Tactile elements for deadfronted glass and methods of making the same

ABSTRACT

Deadfront articles that include a tactile element formed on a first surface of a substrate and a visual element disposed on a second surface of the substrate opposite the first surface. The tactile element is positioned on the first surface of the substrate in a complimentary fashion to the visual element disposed on the second surface of the substrate. The tactile element may include a surface roughness portion having a surface roughness different than the surface roughness of an area bordering the surface roughness portion. The deadfront articles may be incorporated into an automobile interior to provide a visual and haptic display interface for a user.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation and claims the benefit of priorityunder 35 USC § 120 of U.S. patent application Ser. No. 16/646,732 filedon Mar. 12, 2020, which is a national stage application under 35 U.S.C.§ 371 of International Patent Application Serial No. PCT/US2018/050772filed on Sep. 12, 2018, which claims the benefit of priority under 35U.S.C. § 119 of U.S. Provisional Application Ser. No. 62/729,695 filedon Sep. 11, 2018, U.S. Provisional Application Ser. No. 62/679,278 filedon Jun. 1, 2018 and U.S. Provisional Application Ser. No. 62/557,502filed on Sep. 12, 2017, the contents of each is relied upon andincorporated herein by reference in their entirety.

BACKGROUND Field

The present disclosure relates to a deadfront article for displaymethods and apparatus for providing improved visual and optionallytactile features on a substrate. More particularly, the disclosurerelates to deadfront articles with a tactile feel on the front surfaceof the deadfront article.

Background

In recent years, consumer products, including automobile interiorcomponents, have been incorporating more touch screen and deadfront typecontrol displays and less push-button and knob oriented controls. Adeadfront article includes a surface that exhibits a deadfront effect inwhich the surface disguises or masks underlying display features from aviewer when the article is not backlit, but permits the display featuresto be viewed when the article is backlit.

Accordingly, a need exists for innovations in touch screen and deadfronttype control displays.

SUMMARY

The present disclosure is related to deadfront articles for consumerproducts that provide a decorative surface with a tactile feel.Disclosed deadfront articles may be incorporated into a consumer productto provide a surface with a decorative appearance (e.g., stainlesssteel, wood, etc.), a tactile feel, and underlying control features(e.g., display buttons/icons). Disclosed deadfront articles may be usedto make sleek, lightweight, strong, decorative, and functional surfaceswith a tactile feel in various industries. For example, discloseddeadfront articles may be used in the automotive industry to provide adeadfronted control display with a haptic features for automobileinteriors.

In a first aspect a deadfront article is described, the deadfrontarticle including a substrate having a first surface and a secondsurface opposite the first surface; a visual element disposed on thesecond surface of the substrate and/or within the substrate such thatthe visual element may be viewed through the first surface, the visualelement including a graphic that may be viewed through the firstsurface; at least one tactile element formed on the first surface of thesubstrate, the at least one tactile element comprising one or moresurface roughness portions, where at least one of the one or moresurface roughness portions is positioned on the first surface of thesubstrate in a complimentary fashion to the graphic; a semi-transparentlayer disposed on at least a first portion of the second surface of thesubstrate, the semi-transparent layer having a region of a solid coloror of a design of two or more colors; and a contrast layer disposed onat least a portion of the region, the contrast layer configured toenhance visibility of the color of the region or to enhance contrastbetween the colors of the design of the region on the portion of theregion on which the contrast layer is disposed.

In a second aspect, the deadfront article according to aspects of thepreceding paragraph may include one or more surface roughness portionsare defined by one of: (i) an area of relatively higher surfaceroughness bordered by at least one area of relatively lower surfaceroughness, and (ii) an area of relatively lower surface roughnessbordered by at least one area of relatively higher surface roughness.

In a third aspect, the deadfront article according to aspects of any ofthe preceding paragraphs may include a graphic that includes an icon.

In a forth aspect, the deadfront article according to aspects of any ofthe preceding paragraphs may include one or more surface roughnessportions that include an etched portion of the first surface of thesubstrate.

In a fifth aspect, the deadfront article according to aspects of any ofthe preceding paragraphs may include a first surface where the majorityof the total surface area of the first surface of the substrate includesa first surface roughness, and the one or more surface roughnessportions of the tactile element cover a minority of the total surfacearea of the first surface and comprise a second surface roughness, whichis different from the first surface roughness. In some embodiments, thesecond surface roughness may be relatively rougher than the firstsurface roughness. In some embodiments, the second surface roughness mayhave a R_(a) surface roughness of greater than about 80 nm. In someembodiments, the first surface roughness may be relatively rougher thanthe second surface roughness. In some embodiments, the first surfaceroughness may have a R_(a) surface roughness of greater than about 80nm.

In a sixth aspect, the deadfront article according to aspects of any ofthe preceding paragraphs may include a substrate that includes amaterial selected from the group of: a glass, a glass ceramic, and apolymer.

In a seventh aspect, the deadfront article according to aspects of anyof the preceding paragraphs may include a substrate that includesstrengthened glass.

In an eighth aspect, the deadfront article according to aspects of anyof the preceding paragraphs may include a high optical density layerdisposed onto at least a portion of the contrast layer such that thecontrast layer is located between the high optical density layer and thesemi-transparent layer. In some embodiments, the high optical densitylayer at least in part defines the graphic.

In a ninth aspect, the deadfront article according to aspects of any ofthe preceding paragraphs may include a color layer disposed in regionsof the visual element such that, in at least a portion of the visualelement defined by the high optical density layer, the contrast layer islocated between the semi-transparent layer and the color layer.

In a tenth aspect, the deadfront article according to aspects of any ofthe preceding paragraphs may include a semi-transparent layer that has adesign of two or more colors, the design including at least one of aleather grain pattern, a wood grain pattern, a fabric pattern, a brushedmetal finish pattern, and a logo.

In a eleventh aspect, the deadfront article according to aspects of anyof the preceding paragraphs may include a touch panel located behind thevisual element, the touch panel configured to respond to a touch by auser.

In a twelfth aspect, an automobile interior is described, the automobileinterior including a deadfront article including a substrate having afirst surface and a second surface opposite the first surface; a visualelement disposed on the second surface of the substrate and/or withinthe substrate such that the visual element may be viewed through thefirst surface, the visual element including a graphic that may be viewedthrough the first surface; at least one tactile element formed on thefirst surface of the substrate, the at least one tactile elementcomprising one or more surface roughness portions, where at least one ofthe one or more surface roughness portions is positioned on the firstsurface of the substrate in a complimentary fashion to the graphic; asemi-transparent layer disposed on a second surface of the substratelayer; a contrast layer disposed on at least a portion of thesemi-transparent layer; and a high optical density layer disposed on atleast a portion of the contrast layer, the high optical density layer atleast in part defining the graphic; and a touch panel located behind thevisual element, the touch panel configured to respond to a touch by auser.

In a thirteenth aspect, the automobile interior according to aspects ofthe preceding paragraph may include a graphic that is an icon and thetouch panel is configured to respond to a user's touch of the icon.

In a fourteenth aspect, the automobile interior according to aspects ofeither of the two preceding paragraphs may include a semi-transparentlayer that has a region of a solid color or of a design of two or morecolors, the design including at least one of a leather grain pattern, awood grain pattern, a fabric pattern, a brushed metal finish pattern,and a logo.

In a fifteenth aspect, the automobile interior according to aspects ofany of the three preceding paragraphs may include a high optical densitylayer disposed onto at least a portion of the contrast layer such thatthe contrast layer is located between the high optical density layer andthe semi-transparent layer.

In a sixteenth aspect, the automobile interior according to aspects ofany of the four preceding paragraphs may include a color layer disposedin regions of the visual element such that, in at least a portion of thevisual element defined by the high optical density layer, the contrastlayer is located between the semi-transparent layer and the color layer.

In a seventeenth aspect, a method of forming a tactile element on adeadfront article is described, the method including forming at leastone tactile element on a first surface of a substrate in a complimentaryfashion to a graphic defined by a visual element disposed on a secondsurface of the substrate opposite the first surface and/or within thesubstrate such that the graphic may be viewed through the first surface,where the at least one tactile element is formed by a process includingat least one of etching, sandblasting, polishing, and engraving.

In an eightieth aspect, the method according to aspects of the precedingparagraph may include forming the at least one tactile element by anetching process. In some embodiments, the etching process may includeetching the first surface with a first etching solution; disposing amask over the first surface after etching the first surface with thefirst etching solution, the mask comprising a shape corresponding to theshape of the graphic; and etching an unmasked region of the firstsurface with a second etching solution. In some embodiments, the firstetching solution may include hydrofluoric acid, ammonium fluoride, and awater miscible organic solvent, and the second etching solution mayinclude hydrofluoric acid.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from that description or recognized by practicing theembodiments as described herein, including the detailed descriptionwhich follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary, and areintended to provide an overview or framework to understanding the natureand character of the claims. The accompanying drawings are included toprovide a further understanding, and are incorporated in and constitutea part of this specification. The drawings illustrate one or moreembodiment(s), and together with the description serve to explainprinciples and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle interior with vehicle interiorsystems utilizing a deadfront article according to one or more of theembodiments discussed herein.

FIG. 2 shows a display with a solid color deadfront article with thedisplay turned off, according to an exemplary embodiment.

FIG. 3 shows the display with the deadfront article of FIG. 2 with thedisplay turned on, according to an exemplary embodiment.

FIG. 4 shows a display with a patterned deadfront article with thedisplay turned off, according to an exemplary embodiment.

FIG. 5 shows the display with the deadfront article of FIG. 4 with thedisplay turned on, according to an exemplary embodiment.

FIG. 6 is a side cross-sectional view of a deadfront article for adisplay having a semi-transparent layer and a contrast layer, accordingto an exemplary embodiment.

FIG. 7 is another side-sectional view of a deadfront article for displayhaving a functional surface layer and an opaque layer, according to anexemplary embodiment.

FIG. 8 is a side-sectional view of an LED display including a deadfrontarticle, according to an exemplary embodiment.

FIG. 9 is a side-sectional view of a DLP MEMS chip including a deadfrontarticle, according to an exemplary embodiment.

FIG. 10 is a side-sectional view of a deadfront display withtouch-screen functionality, according to an exemplary embodiment.

FIG. 11 is a leather grain deadfront display for a vehicle interior,according to an exemplary embodiment.

FIG. 12 is a wood grain deadfront display for a vehicle interior,according to an exemplary embodiment.

FIGS. 13A and 13B depict the front and back of a glass layer having asemi-transparent layer printed thereon.

FIGS. 14A and 14B depict the front and back of a glass layer having asemi-transparent layer and contrast layer printed thereon, according toan exemplary embodiment.

FIG. 15 depicts contrast layers of varying whiteness printed onto aglass sheet, according to an exemplary embodiment.

FIG. 16 is a graph of transmittance for contrast layers of varyingtransmittance, according to an exemplary embodiment.

FIG. 17 depicts four differently-patterned semi-transparent layers for adeadfront article, according to an exemplary embodiment.

FIG. 18 depicts a deadfront article having a semi-transparent layer thattransitions from leather grain to solid black, according to an exemplaryembodiment.

FIG. 19 depicts a knit-patterned semi-transparent layer for a deadfrontarticle.

FIG. 20 depicts a knit-patterned semi-transparent layer for a deadfrontarticle behind which a contrast layer is printed, according to anexemplary embodiment.

FIGS. 21 and 22 depict the front and back of a deadfront article havinga marble-patterned semi-transparent layer with a window in the contrastlayer, according to an exemplary embodiment.

FIG. 23 is a side view of a curved glass deadfront article for use witha display, according to an exemplary embodiment.

FIG. 24 is a front perspective view of a glass layer for the glassdeadfront article of FIG. 6 prior to curve formation, according to anexemplary embodiment.

FIG. 25 shows a curved deadfront article including a glass layer shapedto conform to a curved display frame, according to an exemplaryembodiment.

FIG. 26 shows a process for cold forming a deadfront article including aglass layer to a curved shape, according to an exemplary embodiment.

FIG. 27 shows a process for forming a curved deadfront article includinga curved glass layer, according to an exemplary embodiment.

FIG. 28 is an exploded view of the layers of a deadfront article,according to an exemplary embodiment.

FIG. 29 depicts a wood grain deadfront article, according to anexemplary embodiment.

FIG. 30 depicts a wood grain deadfront article with a lighted back,according to an exemplary embodiment.

FIG. 31 depicts a wood grain deadfront article with a lighted back andicons of different colors, according to an exemplary embodiment.

FIG. 32 depicts a carbon fiber pattern deadfront article in which theopacity is too high.

FIG. 33 depicts the deadfront article of FIG. 32 with a lighted back,demonstrating that the high level of opacity obscures the icons.

FIG. 34 depicts a carbon fiber pattern deadfront article having anopacity within the disclosed range, according to an exemplaryembodiment.

FIG. 35 depicts the deadfront article of FIG. 34 with a lighted back,demonstrating the better visibility of the icons.

FIG. 36 depicts a deadfront article having a touch panel, according toan exemplary embodiment.

FIG. 37 depicts a top view and a perspective view of a substrate articlehaving both visual and tactile features.

FIGS. 38 and 39 depict schematic images of a substrate as it movesthrough a process for disposing visual and tactile features thereon.

FIG. 40 depicts schematic images of a substrate as it moves through analternative process for disposing visual and tactile features thereon.

FIG. 41 depicts a backlit deadfront article with a visual elementvisible through a surface of the article.

FIG. 42 depicts tactile elements on a surface of a deadfront articlewhen the article is not backlit.

DETAILED DESCRIPTION

Referring generally to the figures, vehicle interior systems may includea variety of different flat or curved surfaces that are designed to betransparent, such as flat or curved display surfaces, and the presentdisclosure provides articles and methods for forming these flat orcurved surfaces. In one or more embodiments, such surfaces are formedfrom glass materials or from plastic materials. Forming curved or flatvehicle surfaces from a glass material may provide a number ofadvantages compared to the typical curved or flat plastic panels thatare conventionally found in vehicle interiors. For example, glass istypically considered to provide enhanced functionality and userexperience for many flat or curved cover material applications, such asdisplay applications and touch screen applications, compared to plasticcover materials.

Further, it is considered desirable in many applications to equipdisplays, and particularly displays for vehicle interior systems, with adeadfront appearance. In general, a deadfront appearance blocksvisibility of underlying display components, icons, graphics, etc. whenthe display is off, but allows display components to be easily viewedwhen the display is on or activated (in the case of a touch-enableddisplay). In addition, an article that provides a deadfront effect(i.e., a deadfront article) can be used to match the color or pattern ofthe article to adjacent components to eliminate the visibility oftransitions from the deadfront article to the surrounding components.This can be especially useful when the deadfront article is a differentmaterial from the surrounding components (e.g., the deadfront article isformed from a glass material but surrounded by a leather-covered centerconsole). For example, a deadfront article may have a wood grain patternor a leather pattern can be used to match the appearance of the displaywith surrounding wood or leather components of a vehicle interior system(e.g., a wood or leather dashboard) in which the display is mounted.

Various embodiments of the present disclosure relate to the formation ofa curved glass-based deadfront article utilizing a cold-forming orcold-bending process. As discussed herein, curved glass-based deadfrontarticles and processes for making the same are provided that avoid thedeficiencies of the typical glass hot-forming process. For example,hot-forming processes are energy intensive and increase the cost offorming a curved glass component, relative to the cold-bending processesdiscussed herein. In addition, hot-forming processes typically makeapplication of glass coating layers, such as deadfront ink or pigmentlayers, more difficult. For example, many ink or pigment materialscannot be applied to a flat piece of glass material prior to thehot-forming process because the ink or pigment materials typically willnot survive the high temperatures of the hot-forming process. Further,application of an ink or pigment material to surfaces of a curved glassarticle after hot-bending is substantially more difficult thanapplication to a flat glass article.

Various embodiments of the present disclosure relate to deadfrontedarticles with areas of tactile feel on the front surface. As the use oftouch screen and deadfront types displays increases, the importance ofaesthetic features and the integration of form and function, alsoincreases. An deadfront article that facilitates both visual and tactileinteraction with a user makes interaction with article more convenientfor a user. A deadfront article with areas of tactile fell can create“invisible” controls for a user on a decorated surface having theappearance of any material imagined (e.g., carbon fiber, stainlesssteel, wood, etc.) when the deadfront article is off.

FIG. 1 shows a vehicle interior 10 that includes three different vehicleinterior systems 100, 200, 300, according to an exemplary embodiment.Vehicle interior system 100 includes a center console base 110 with aflat or curved surface 120 including a display, shown as flat or curveddisplay 130. Vehicle interior system 200 includes a dashboard base 210with a curved surface 220 including a display, shown flat or curveddisplay 230. The dashboard base 210 typically includes an instrumentpanel 215 which may also include a flat or curved display. Vehicleinterior system 300 includes a dashboard steering wheel base 310 with acurved surface 320 and a display, shown as a flat or curved display 330.In one or more embodiments, the vehicle interior system may include abase that is an arm rest, a pillar, a seat back, a floor board, aheadrest, a door panel, or any portion of the interior of a vehicle thatincludes a curved surface.

The embodiments of the deadfront articles described herein can be usedin any or all of vehicle interior systems 100, 200 and 300. While FIG. 1shows an automobile interior, the various embodiments of the vehicleinterior system may be incorporated into any type of vehicle such astrains, automobiles (e.g., cars, trucks, buses and the like), sea craft(boats, ships, submarines, and the like), and aircraft (e.g., drones,airplanes, jets, helicopters and the like), including both human-pilotedvehicles, semi-autonomous vehicles and fully autonomous vehicles.Further, while the description herein relates primarily to the use ofthe deadfront embodiments used in vehicle displays, it should beunderstood that various deadfront embodiments discussed herein may beused in any type of display application. For example, deadfrontedarticles with areas of tactile feel may be incorporated into an articlewith a display (or display articles) (e.g., consumer electronicproducts, including mobile phones, tablets, computers, navigationsystems, wearable devices (e.g., watches and the like)), architecturalarticles (e.g., a window or window assembly), or appliance articles(e.g., refrigerators or ranges).

Referring to FIG. 2 and FIG. 3 , a deadfront article 400 for a vehicledisplay, such as displays 130, 230 and/or 330, is shown and described.FIG. 2 shows the appearance of deadfront article 400 when a light sourceof the associated display is inactive, and FIG. 3 shows the appearanceof deadfront article 400 when a light source of the associated displayis active. As shown in FIG. 3 , with the light source activated, agraphic 410 and/or a plurality of icons are visible through thedeadfront article. When the light source is inactivated, the graphic 410disappears, and deadfront article 400 presents a surface showing adesired surface finish (e.g., a black surface in FIG. 2 ) that isunbroken by graphics 410. In some embodiments, the light source isactivated using a power button 420. As shown in the embodiments of FIGS.2 and 3 , the power button 420 may be lighted and changes from red togreen when activated. In exemplary embodiments, the power button 420 isselected to conform with one of IEC 60417-5007, IEC 60417-5008, IEC60417-5009, and IEC 60417-5010.

FIGS. 4 and 5 depict another embodiment of a deadfront article 400 for avehicle display, such as displays 130, 230 and/or 330. In comparison tothe solid color deadfront article 400 of FIG. 2 , a patterned deadfrontarticle 400 is depicted in FIG. 4 . When a light source of theassociated display is inactive as in FIG. 4 , only the pattern of thedeadfront article 400 can be seen. In FIG. 3 , the light source of theassociated display is active and icons 430 can be seen through thedeadfront article 400. Thus, when the light source is inactivated, icons430 disappear, and deadfront article 400 presents a surface showing adesired pattern (e.g., a leather grain pattern in FIG. 4 ) that isunbroken by icons 430.

As will be discussed in more detail below, deadfront article 400provides this differential icon display by utilizing one or more coloredlayers disposed between an outer substrate and a light source. Theoptical properties of the colored layers are designed such that when thelight source is turned off the borders of the icons or other displaystructures beneath the colored layer are not visible, but when the lightsource is on, graphics 410 and/or icons 430 are visible. In variousembodiments, the deadfront articles discussed herein are designed toprovide a high quality deadfront appearance, including high contrasticons with the light source on, combined with a uniform deadfrontappearance when the light is off. Further, these various deadfrontarticles may be formed using materials suitable for cold forming tocurved shapes, including complex curved shapes, as discussed below.

Referring now to FIG. 6 , an embodiment of the structure of thedeadfront article 400 is provided. In particular, the deadfront article400 includes at least a substrate 450, a semi-transparent layer 460, anda contrast layer 470. Semi-transparent layer 460 may include a region ofsolid color or a design of two or more colors. The solid color or designof two or more colors of semi-transparent layer may produce a decorativecolor or pattern for deadfront article 400 (e.g., wood-grain design, aleather-grain design, a fabric design, a brushed metal design, a graphicdesign, a solid color and/or a logo). Contrast layer 470 may beconfigured to enhance the visibility of the color of semi-transparentlayer 460 and/or enhance contrast between the colors of semi-transparentlayer 460.

The substrate 450 has an outer surface 480 facing a viewer and an innersurface 490 upon which the semi-transparent layer 460 and/or thecontrast layer 470 are, at least in part, disposed. As used herein, theterm “dispose” includes coating, depositing and/or forming a materialonto a surface using any known method in the art. The disposed materialmay constitute a layer, as defined herein. As used herein, the phrase“disposed on” includes the instance of forming a material onto a surfacesuch that the material is in direct contact with the surface and alsoincludes the instance where the material is formed on a surface, withone or more intervening material(s) is between the disposed material andthe surface. The intervening material(s) may constitute a layer, asdefined herein. The term “layer” may include a single layer or mayinclude one or more sub-layers. Such sub-layers may be in direct contactwith one another. The sub-layers may be formed from the same material ortwo or more different materials. In one or more alternative embodiments,such sub-layers may have intervening layers of different materialsdisposed therebetween. In one or more embodiments a layer may includeone or more contiguous and uninterrupted layers and/or one or morediscontinuous and interrupted layers (i.e., a layer having differentmaterials formed adjacent to one another). A layer or sub-layers may beformed by any known method in the art, including discrete deposition orcontinuous deposition processes. In one or more embodiments, the layermay be formed using only continuous deposition processes, or,alternatively, only discrete deposition processes.

While the specifics of the substrate 450 will be discussed in greaterdetail below, in some embodiments the substrate 450 has a thickness offrom 0.05 to 2.0 mm (millimeters). In one or more embodiments, thesubstrate may be a transparent plastic, such as PMMA, polycarbonate andthe like, or may include glass material (which may be optionallystrengthened). As will also be discussed more fully below, in someembodiments the semi-transparent layer 460 is printed onto at least aportion of the inner surface 490 of the substrate 450. In otherembodiments, the semi-transparent layer 460 is deposited usingnon-conductive vacuum metallization. Further, in some embodiments, thecontrast layer 470 is printed onto at least a portion of the innersurface 490 of the substrate 450 and/or onto at least a portion of thesemi-transparent layer 460.

In certain embodiments, such as shown in FIG. 7 , the deadfront article400 also includes a functional surface layer 500 and/or an opaque layer510 (also referred to as “high optical density layer”). The functionalsurface layer 500 can be configured to provide one or more of a varietyof functions. In another exemplary embodiment, the functional surfacelayer 500 is an optical coating configured to provide easy-to-cleanperformance, anti-glare properties, anti-reflection properties, and/orhalf-mirror coating. Such optical coatings can be created using singlelayers or multiple layers. In the case of anti-reflection functionalsurface layers, such layers may be formed using multiple, layers havingalternating high refractive index and low refractive index. Non-limitingexamples of low-refractive index materials include SiO₂, MgF₂, andAl₂O₃, and non-limiting examples of high-refractive index materialsinclude Nb₂O₅, TiO₂, ZrO₂, HfO₂, and Y₂O₃. In some embodiments, thetotal thickness of such an optical coating (which may be disposed overan anti-glare surface or a smooth substrate surface) is from 5 nm to 750nm. Additionally, in some embodiments, the functional surface layer 500that provides easy-to-clean performance provides enhanced feel for touchscreens and/or coating/treatments to reduce fingerprints. In someembodiments, functional surface layer 500 is integral to the outersurface 480 of the substrate. For example, such functional surfacelayers can include an etched surface in the outer surface 480 of thesubstrate 450 providing an anti-glare surface (or haze of from, e.g., 2%to 20%). The functional surface layer 500, if provided, along with thesubstrate 450, the semi-transparent layer 460, and the contrast layer470 together comprise the semi-transparent structure 520 of thedeadfront article 400.

As will be discussed more fully below, the opaque layer 510 has highoptical density in order to block light transmittance. As used herein,“opaque layer” is used interchangeably with “high optical densitylayer.” In some embodiments, the opaque layer 510 is used to block lightfrom transmitting through certain regions of the deadfront article 400.In certain embodiments, the opaque layer 510 obscures functional ornon-decorative elements provided for the operation of the deadfrontarticle 400. In other embodiments, the opaque layer 510 is provided tooutline backlit icons and/or other graphics (such as the graphic 410and/or power button 420 shown in FIGS. 2 and 3 and the icons 430 shownin FIG. 5 ) to increase the contrast at the edges of such icons and/orgraphics. Thus, in some embodiments, the opaque layer 510 hasinterruptions in the layer that define a window for the graphic(s) 410,power button(s) 420, and/or icon(s) 430. That is, in some embodiments,the opaque layer 510 extends continuously until an edge of a perimeterfor a graphic 410, power button 420, and/or icon 430 is reached. At sucha perimeter edge, the opaque layer 510 stops, or in some embodiments,substantially decreases in optical density (e.g., thins in materialthickness, decreases in material density, etc.). In some embodiments,the opaque layer 510 resumes intermittently in the region of the graphic410, power button 420, and/or icon 430 to define features of the graphic410, power button 420, and/or icon 430, such as to define the “l” and“O” of certain power buttons 420, for example. Accordingly, in someembodiments, the opaque layer 510 defines an image negative for thegraphic 410, power button 420, and/or icon 430 in that the portions ofthe graphic 410, power button 420, and/or icon 430 visible by the userthrough the outer surface 480 of the substrate 450 are blank regions ofthe opaque layer 510.

The opaque layer 510 can be any color; in particular embodiments,though, the opaque layer 510 is black or gray. In some embodiments, theopaque layer 510 is applied via screen printing or inkjet printing overthe semi-transparent layer 460 and/or over the inner surface 490 of thesubstrate 450. Generally, the thickness of an inkjet-printed opaquelayer 510 is from 1 μm to 5 μm (micrometers, microns), whereas thethickness of a screen-printed opaque layer 510 is from 5 μm to 20 μm.Thus, a printed opaque layer 510 can have a thickness in the range offrom 1 μm to 20 μm. However, in other embodiments, the opaque layer 510is a metal layer deposited via physical vapor deposition and/or is anoptical stack produced using the high/low-index stacking discussed abovefor color matching.

FIG. 28 provides an exploded view of the layers comprising the deadfrontarticle 400 in an embodiment. As can be seen, the layers include thesubstrate 450, the semi-transparent layer 460, the contrast layer 470,the opaque layer 510, and a color layer 650. As can be seen in FIG. 28 ,the semi-transparent layer 460 is a woodgrain pattern, and the opaquelayer 510 provides negative images for icons 430, e.g., for anentertainment console, such as a power button 420, tuning controls,volume control, presets, etc. The combination of the semi-transparentlayer 460, the contrast layer 470, and the opaque layer 510 provide adeadfront article 400 such as is shown in FIGS. 29 and 30 . In FIG. 29 ,the woodgrain of the semi-transparent layer 460 is seen when thedeadfront article 400 is not backlit, and when the deadfront article 400is backlit, the icons 430 are visible through the outer surface 480 ofthe deadfront article 400. Referring again to FIG. 28 , when the colorlayer 650 is disposed on the opaque layer 510 (at least in the regionsof the icons 430) the color of the icons 430 can be changed as shown inFIG. 31 . Further, while a solid color layer 650 is depicted in FIG. 28, the color layer 650 can include multiple colors across the layer asshown in FIG. 31 and/or specific colors in regions of specific icons 430or portions of icons 430. In this way, the color layer 650 is acontinuous layer in some embodiments, and in other embodiments, thecolor layer 650 is discontinuous, i.e., color is only provided incertain locations over the opaque layer 510 and/or contrast layer 470 inregions that define the icons 430.

In some embodiments, the optical densities of the layers are tailored toenhance the visibility of the graphics 410, power button 420, and/oricons 430 when the deadfront article 400 is backlit. In particularembodiments, the combined optical density of the semi-transparent layer460 and the contrast layer 470 in illuminated regions (i.e., the graphic410, the power button 420, and/or the icons 430) is from 1.0 to 2.1. Inother embodiments, the combined optical density is 1.2 to 1.6, and instill other embodiments, the combined optical density is about 1.4. Inproviding the optical density of the illuminated regions, the opticaldensity of the contrast layer 470 is from 0.9 to 2.0 in someembodiments, and the optical density of the semi-transparent layer 460is 0.1 to 0.5 in some embodiments. In the non-illuminated regions (i.e.,the regions surrounding the graphic 410, the power button 420, and/orthe icons 430), the combined optical density of the semi-transparentlayer 460, the contrast layer 470, and the opaque layer 510 is at least3.4. In providing the optical density of the non-illuminated regions,the optical density of the contrast layer 470 is from 0.9 to 2.0 in someembodiments, the optical density of the semi-transparent layer 460 isfrom 0.1 to 0.5 in some embodiments, and the optical density of theopaque layer 510 is at least 2.4 in some embodiments. In exemplaryembodiments, the optical density of the color layer 650 is from 0.3 to0.7. Further, in some embodiments, the optical density of a particularlayer can vary across the layer to provide enhanced contrast or toconserve the ink or material comprising the layer. For example, theoptical density of the contrast layer 470 can be lower in illuminatedregions than in non-illuminated regions. Additionally, the opticaldensity of the color layer 650 can be lower (or zero) in non-illuminatedregions than in illuminated regions.

FIGS. 32 and 33 and FIGS. 34 and 35 show different deadfront articleshaving different levels of optical density, and thus, these figuresdemonstrate the different appearance between deadfront articles 400 inwhich the optical density is too high in the illuminated regions (FIGS.32 and 33 ) and in which the optical density is within theabove-described ranges for the illuminated regions (FIGS. 34 and 35 ).As can be seen in FIG. 32 , the deadfront article has a carbon fiberpattern in which the optical density of the semi-transparent layer istoo high. Thus, as can be seen in FIG. 33 , the illuminated region isobscured. By comparison, the deadfront article 400 in FIG. 34 has beenprovided with a carbon fiber pattern with a semi-transparent layer 460,contrast layer 470, and opaque layer 510 that have optical densitieswithin the above-described ranges. Thus, as shown in FIG. 35 , the icons430 are much more defined and are clearly visible. Also as shown in FIG.35 , the center icon 430 is a power button 420 that has been providedwith a red color using a color layer 650.

As shown in FIGS. 8 and 9 , the deadfront article 400 may be placed overor in front of a display 530 in some embodiments. In one or moreembodiments, the display may include a touch-enabled displays whichinclude a display and touch panel. Exemplary displays include LED (lightemitting diode) displays (FIG. 8 ), a DLP (digital micromirror device)MEMS chip (FIG. 9 ), LCDs (liquid crystal displays), OLED (organic lightemitting diode) displays, transmissive displays, reflective displays andthe like. In some embodiments, the display 530 is affixed or mounted tothe deadfront article 400 using, e.g., an optically clear adhesive 540.The deadfront article 400 has a transmittance from about 5% to 30% alongthe visible spectrum, i.e., a wavelength from 400 nm to 700 nm. In otherwords, the deadfront article 400 exhibits an average light transmittancein a range from about 5% to about 30% along the entire wavelength rangefrom about 400 nm to about 700 nm. As used herein, the term“transmittance” is defined as the percentage of incident optical powerwithin a given wavelength range transmitted through a material (e.g.,the deadfront article, the substrate or the layers thereof). In someembodiments, the deadfront article 400 is a low transmittance deadfrontarticle in which light transmission is 10% or less over the entirevisible spectrum. In such instances, the opaque layer 510 may not benecessary to obscure the edges of the display 530, i.e., non-displayregions, such as a display border, and/or wiring, connectors, etc. Inother embodiments, the deadfront article 400 is a high transmittancedeadfront article exhibiting an average transmittance from about 10% toabout 30%. In such embodiments, the opaque layer 510 may be necessary toblock non-display regions from being seen.

In certain embodiments, the deadfront article 400 is provided with touchfunctionality as shown in FIG. 10 . In FIG. 10 , the deadfront article400 includes substrate 450, a black semi-transparent layer 460, and acontrast layer 470 that is disposed on portions of the substrate 450 andof the semi-transparent layer 460. In this way, the contrast layer 470and the semi-transparent layer 460 define an icon or a graphic, such asa power button 420 (e.g., as shown in FIGS. 2 and 3 ). In an embodiment,touch functionality is provided by capacitive sensing. In certainembodiments, the capacitive sensor is created by a transparentconductive film or coating 550. In an exemplary embodiment, thetransparent conductive film 550 is a transparent conductive oxide (e.g.,indium-tin-oxide (ITO)) coated polyester (e.g., PET) film.

Upon activation of a toggle switch (e.g., by touching the deadfrontarticle 400 in the region of the transparent conductive film 550), alight source 570 is activated or deactivated 570. In the embodiment ofFIG. 10 , the light source 570 includes a red LED 580 and a green LED590. In certain settings, such as a vehicle, the red LED 580 and greenLED 590 indicate the status of the deadfront article 400. For example,prior to turning the vehicle on, both the red LED 580 and green LED 590are off as shown at the bottom of the legend of the power button 420states on the left of FIG. 10 . When the vehicle is turned on and priorto touching the power button 420, the red LED 580 is on while the greenLED 590 is off (top of the legend of power button 420 states),signifying that the display 530 is inactive. Upon touching the powerbutton 420, the toggle switch 560 will turn off the red LED 580, turn onthe green LED 590, and activate the display 530. If the user desires toinactivate the display 530 while the vehicle is still on, the user canagain touch the power button 420, and the toggle switch 560 will turnoff the green LED 590, turn on the red LED 580, and shut off the display530. In certain embodiments, a vibration motor 600 is provided toprovide haptic feedback each time the toggle switch 560 is activated.

While the exemplary embodiment of a power button 420 for a display 530was provided, the touch-functionality is suitable for other features.Continuing with the example of a vehicle, the touch-functionality issuitable for use in controlling a variety of vehicle systems, such asclimate control (i.e., heating and air conditioning) systems,radio/entertainment systems, dashboard display panels (for, e.g.,speedometer, odometer, trip odometer, tachometer, vehicle warningindicators, etc.), and center console display panels (for, e.g., GPSdisplays, in-vehicle information, etc.), among others. In FIG. 11 , thedeadfront article 400 is depicted with a speedometer 610 and climatecontrols 620. The deadfront article 400 includes a leather grainpattern. FIG. 12 provides a substantially similar deadfront article 400with a speedometer 610 and climate controls 620, but the deadfrontarticle 400 includes a wood grain pattern.

In particular embodiments, the substrate 450 is treated (e.g., viasandblasting, etching, engraving, etc.) in the area of a button toprovide tactile feedback to a user's finger. In this way, the user canfeel the deadfront article 400 for the button without removing his orher eyes from the road (in road vehicle settings). Further, in someembodiments, the toggle switch 560 is provided with a delay of, e.g.,one to three seconds so as to avoid accidental activation of the toggleswitch 560.

FIG. 36 provides another embodiment of a deadfront article 400 withtouch functionality. In particular, the deadfront article 400 includes atouch panel 660. The touch panel 660 can be any of a variety of suitabletouch panels, such as a resistive touch panel, a capacitive (e.g.,surface or projected) touch panel, a surface acoustic wave touch panel,an infrared touch panel, an optical imaging touch panel, dispersivesignal touch panel, or an acoustic pulse recognition touch panel. Insome embodiments, the touch panel 660 is laminated to the deadfrontarticle 400 using an optically clear adhesive 540. In other embodiments,the touch panel 660 is printed onto the deadfront article 400 such thatthe optically clear adhesive 540 is unnecessary. Advantageously, thetouch panel 660 is cold bendable to provide a three-dimensional shape.Cold bending of the deadfront article 400 (including the touch panel660) is described in greater detail further below.

Having described generally the structure of the deadfront article 400,attention will be turned to the semi-transparent layer 460 and thecontrast layer 470. As mentioned above, the semi-transparent layer 460and the contrast layer 470 are disposed on the substrate 450. In someembodiments, the semi-transparent layer 460 is printed onto thesubstrate using a CMYK color model. In some embodiments in which thecontrast layer is not white, such as gray, the CMYK color model can alsobe used to print the contrast layer 470. In other embodiments in whichthe contrast layer 470 is white, color models that incorporate white inkcan be used for printing the contrast layer 470. The printedsemi-transparent layer 460 and the printed contrast layer 470 may eachhave a thickness of from 1 μm to 6 μm. In some embodiments, the colorlayer 650 also has a thickness of from 1 μm to 6 μm. Further, in someembodiments, the color layer 650 is printed onto the opaque layer 510and/or the contrast layer 470. In certain embodiments, the color layer650 is printed onto the opaque layer 510 and/or contrast layer 470 usingthe CMYK color model.

The ink used for printing the semi-transparent layer 460, the contrastlayer 470, and/or the color layer 650 can be thermal or UV cured ink. Inparticular, the ink is composed of at least one or more colorants and avehicle. The colorants can be soluble or insoluble in the vehicle. Insome embodiments, the colorants are dry colorants in the form of a finepowder. Such fine powders have particles that are, in some embodiments,from 10 nm to 500 nm in size. Using the CMYK color model, the colorantprovides cyan, magenta, yellow, and/or key (black) colors. For whiteinks, the colorant can be any of a variety of suitable pigments, such asTiO₂, Sb₂O₃, BaSO₄, BaSO₄:ZnS, ZnO, and (PbCO₃)₂:Pb(OH)₂. The colorantsare dissolved or suspended in the vehicle.

The vehicle can serve as a binder to create adhesion to the surface uponwhich the ink is applied. Further, in some embodiments, additives areincluded in the vehicle specifically for the purpose of improvingadhesion to glass/plastic surfaces. Non-limiting examples of vehiclesfor the colorant include propylene glycol monomethyl ether, diethyleneglycol diethyl ether, dimethylacetamide, and toluene. Generally, suchvehicles solidify at temperatures from 80° C. to 200° C. In someembodiments, the ink includes from 0.5%-6% by volume of the colorant and94%-99.5% by volume of the vehicle.

As shown in FIGS. 13A and 13B, a leather grain semi-transparent layer460 was printed on to the substrate 450, specifically using an inkjetprinter according to a CMYK color model (although, in other embodiments,other printer types and/or printing models are used). In FIGS. 14A and14B, a white contrast layer 470 was printed behind the semi-transparentlayer 460. FIGS. 13B and 14B depict the back sides of these printedlayers. As can be seen in a comparison of FIGS. 13A and 14A, thecontrast of the leather grain pattern of the semi-transparent layer 460is enhanced by the white contrast layer 470 in FIG. 14A. Indeed, usingthe contrast layer 470, the overall appearance of the pattern or designin the semi-transparent layer 460 is brighter, and the contrast betweenthe colors in the pattern or design is enhanced.

The thickness and composition of the contrast layer 470 is tunable toexhibit a particular transmittance in the visible and infraredwavelength range. FIG. 15 depicts contrast layers 470 printed over aglass background. The contrast layers 470 are of varying whiteness (W).“Whiteness” as used herein refers to the CIE whiteness, or ISO11475:2004, which measures the amount of light reflected by a whitesurface over the visible spectrum (wavelength of 400 nm to 700 nm). Thelower left corner of FIG. 15 is a contrast layer of 100 W. The whitenessof the contrast layer 470 decreases from 100 W to 60 W going left toright along the bottom row, and along the top row, whiteness decreasesfrom 50 W to 10 W going left to right. As can be seen, relatively lowerwhiteness contrast layers 470 transmit more light than relatively higherwhiteness contrast layer 470. This is also demonstrated in thetransmittance (T) graph of FIG. 16 . As the whiteness increases, thepercent transmittance (% T) across the visible spectrum decreases. Thedata for generating the graph of FIG. 16 was calculated after printingwhite ink having diethylene glycol diethyl ether solvent and using a 128nozzle, 40 pL printhead. The transmittance (T) is controlled throughmanipulation of printing resolution and layer thickness. In someembodiments, the deadfront article 400 is provided with a contrast layer470 having a whiteness of between 10 W and 60 W. In other embodiments,the contrast layer 470 has a whiteness of between 20 W and 50 W. In aparticular embodiment, the contrast layer 470 has a whiteness of between20 W and 30 W.

FIG. 17 depicts four glass substrates 450 having a semi-transparentlayer 460 and contrast layer 470 printed thereon. As can be seen in FIG.17 , the semi-transparent layers 460 feature designs of a knitted fabricpattern, a leather grain pattern, and two wood grain patterns. FIG. 18depicts a semi-transparent layer 460 that transitions from a leathergrain pattern to a solid black pattern. In FIG. 18 , a green powerbutton is also printed in the lower left corner. FIGS. 19 and 20 providea comparison between the same knitted fabric pattern semi-transparentlayer 460. However, in FIG. 20 , a contrast layer 470 was printed behindthe semi-transparent layer 460. In FIG. 20 , the deadfront article 400has a transmittance of between 5% and 10% over the visible spectrum(wavelength of 400 nm to 700 nm). FIGS. 21 and 22 depict a marbledeadfront article 400. In particular, FIG. 21 is the viewer side of thedeadfront article 400, whereas FIG. 22 is the rear side of the deadfrontarticle 400. As can be seen in FIG. 22 , a section of thesemi-transparent layer 460 is not covered with the contrast layer 470.In some embodiments, a display could be mounted to the section notcovered by the contrast layer 470.

Referring to FIGS. 23-27 , various sizes, shapes, curvatures, glassmaterials, etc. for a glass-based deadfront article along with variousprocesses for forming a curved glass-based deadfront are shown anddescribed. It should be understood, that while FIGS. 23-27 are describedin the context of a simplified curved deadfront article 2000 for ease ofexplanation, deadfront article 2000 may be any of the deadfrontembodiments discussed herein.

As shown in FIG. 23 , in one or more embodiments, deadfront article 2000includes a curved outer glass substrate 2010 having at least a firstradius of curvature, R1, and in various embodiments, curved outer glasssubstrate 2010 is a complex curved sheet of glass material having atleast one additional radius of curvature. In various embodiments, R1 isin a range from about 60 mm to about 1500 mm.

Curved deadfront article 2000 includes a deadfront colored layer 2020(e.g., the ink/pigment layer(s), as discussed above) located along aninner, major surface of curved outer glass substrate 2010. In general,deadfront colored layer 2020 is printed, colored, shaped, etc. toprovide a wood-grain design, a leather-grain design, a fabric design, abrushed metal design, a graphic design, a solid color and/or a logo.However, embodiments of the invention are not limited to these designsor patterns. Curved deadfront article 2000 also may include any of theadditional layers 2030 (e.g., high optical density layers, light guidelayers, reflector layers, display module(s), display stack layers, lightsources, touch panels, etc.) as discussed above or that otherwise may beassociated with a display or vehicle interior system as discussedherein.

As will be discussed in more detail below, in various embodiments,curved deadfront article 2000 including glass substrate 2010 and coloredlayer 2020 may be cold-formed together to a curved shape, as shown inFIG. 23 . In some embodiments, curved deadfront article 2000 includingglass substrate 2010, colored layer 2020 and additional layers 2030 maybe cold-formed together to a curved shape, such as that shown in FIG. 23. In other embodiments, glass substrate 2010 may be formed to a curvedshape, and then layers 2020 and 2030 are applied following curveformation.

Referring to FIG. 24 , outer glass substrate 2010 is shown prior tobeing formed to the curved shape shown in FIG. 24 . In general, thearticles and processes discussed herein provide high quality deadfrontarticles utilizing glass of sizes, shapes, compositions, strengths, etc.not previously provided.

As shown in FIG. 24 , outer glass substrate 2010 includes a first majorsurface 2050 and a second major surface 2060 opposite first majorsurface 2050. An edge surface or minor surface 2070 connects the firstmajor surface 2050 and the second major surface 2060. Outer glasssubstrate 2010 has a thickness (t) that is substantially constant and isdefined as a distance between the first major surface 2050 and thesecond major surface 2060. In some embodiments, the thickness (t) asused herein refers to the maximum thickness of the outer glass substrate2010. Outer glass substrate 2010 includes a width (W) defined as a firstmaximum dimension of one of the first or second major surfacesorthogonal to the thickness (t), and outer glass substrate 2010 alsoincludes a length (L) defined as a second maximum dimension of one ofthe first or second surfaces orthogonal to both the thickness and thewidth. In other embodiments, the dimensions discussed herein are averagedimensions.

In one or more embodiments, outer glass substrate 2010 has a thickness(t) that is in a range from 0.05 mm to 2 mm. In various embodiments,outer glass substrate 2010 has a thickness (t) that is about 1.5 mm orless. For example, the thickness may be in a range from about 0.1 mm toabout 1.5 mm, from about 0.15 mm to about 1.5 mm, from about 0.2 mm toabout 1.5 mm, from about 0.25 mm to about 1.5 mm, from about 0.3 mm toabout 1.5 mm, from about 0.35 mm to about 1.5 mm, from about 0.4 mm toabout 1.5 mm, from about 0.45 mm to about 1.5 mm, from about 0.5 mm toabout 1.5 mm, from about 0.55 mm to about 1.5 mm, from about 0.6 mm toabout 1.5 mm, from about 0.65 mm to about 1.5 mm, from about 0.7 mm toabout 1.5 mm, from about 0.1 mm to about 1.4 mm, from about 0.1 mm toabout 1.3 mm, from about 0.1 mm to about 1.2 mm, from about 0.1 mm toabout 1.1 mm, from about 0.1 mm to about 1.05 mm, from about 0.1 mm toabout 1 mm, from about 0.1 mm to about 0.95 mm, from about 0.1 mm toabout 0.9 mm, from about 0.1 mm to about 0.85 mm, from about 0.1 mm toabout 0.8 mm, from about 0.1 mm to about 0.75 mm, from about 0.1 mm toabout 0.7 mm, from about 0.1 mm to about 0.65 mm, from about 0.1 mm toabout 0.6 mm, from about 0.1 mm to about 0.55 mm, from about 0.1 mm toabout 0.5 mm, from about 0.1 mm to about 0.4 mm, or from about 0.3 mm toabout 0.7 mm.

In one or more embodiments, outer glass substrate 2010 has a width (W)in a range from about 5 cm to about 250 cm, from about 10 cm to about250 cm, from about 15 cm to about 250 cm, from about 20 cm to about 250cm, from about 25 cm to about 250 cm, from about 30 cm to about 250 cm,from about 35 cm to about 250 cm, from about 40 cm to about 250 cm, fromabout 45 cm to about 250 cm, from about 50 cm to about 250 cm, fromabout 55 cm to about 250 cm, from about 60 cm to about 250 cm, fromabout 65 cm to about 250 cm, from about 70 cm to about 250 cm, fromabout 75 cm to about 250 cm, from about 80 cm to about 250 cm, fromabout 85 cm to about 250 cm, from about 90 cm to about 250 cm, fromabout 95 cm to about 250 cm, from about 100 cm to about 250 cm, fromabout 110 cm to about 250 cm, from about 120 cm to about 250 cm, fromabout 130 cm to about 250 cm, from about 140 cm to about 250 cm, fromabout 150 cm to about 250 cm, from about 5 cm to about 240 cm, fromabout 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cmto about 190 cm, from about 5 cm to about 180 cm, from about 5 cm toabout 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm,from about 5 cm to about 100 cm, from about 5 cm to about 90 cm, fromabout 5 cm to about 80 cm, or from about 5 cm to about 75 cm.

In one or more embodiments, outer glass substrate 2010 has a length (L)in a range from about 5 cm to about 250 cm, from about 10 cm to about250 cm, from about 15 cm to about 250 cm, from about 20 cm to about 250cm, from about 25 cm to about 250 cm, from about 30 cm to about 250 cm,from about 35 cm to about 250 cm, from about 40 cm to about 250 cm, fromabout 45 cm to about 250 cm, from about 50 cm to about 250 cm, fromabout 55 cm to about 250 cm, from about 60 cm to about 250 cm, fromabout 65 cm to about 250 cm, from about 70 cm to about 250 cm, fromabout 75 cm to about 250 cm, from about 80 cm to about 250 cm, fromabout 85 cm to about 250 cm, from about 90 cm to about 250 cm, fromabout 95 cm to about 250 cm, from about 100 cm to about 250 cm, fromabout 110 cm to about 250 cm, from about 120 cm to about 250 cm, fromabout 130 cm to about 250 cm, from about 140 cm to about 250 cm, fromabout 150 cm to about 250 cm, from about 5 cm to about 240 cm, fromabout 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cmto about 190 cm, from about 5 cm to about 180 cm, from about 5 cm toabout 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm,from about 5 cm to about 100 cm, from about 5 cm to about 90 cm, fromabout 5 cm to about 80 cm, or from about 5 cm to about 75 cm.

As shown in FIG. 23 , outer glass substrate 2010 is shaped to a curvedshaping having at least one radius of curvature, shown as R1. In variousembodiments, outer glass substrate 2010 may be shaped to the curvedshape via any suitable process, including cold-forming and hot-forming.

In specific embodiments, outer glass substrate 2010 is shaped to thecurved shape shown in FIG. 23 , either alone, or following attachment oflayers 2020 and 2030, via a cold-forming process. As used herein, theterms “cold-bent,” “cold-bending,” “cold-formed” or “cold-forming”refers to curving the glass substrate at a cold-form temperature whichis less than the softening point of the glass (as described herein). Afeature of a cold-formed glass substrate is an asymmetric surfacecompressive between the first major surface 2050 and the second majorsurface 2060. In some embodiments, prior to the cold-forming process orbeing cold-formed, the respective compressive stresses in the firstmajor surface 2050 and the second major surface 2060 are substantiallyequal.

In some such embodiments in which outer glass substrate 2010 isunstrengthened, the first major surface 2050 and the second majorsurface 2060 exhibit no appreciable compressive stress, prior tocold-forming. In some such embodiments in which outer glass substrate2010 is strengthened (as described herein), the first major surface 2050and the second major surface 2060 exhibit substantially equalcompressive stress with respect to one another, prior to cold-forming.In one or more embodiments, after cold-forming (shown, for example, inFIG. 23 ) the compressive stress on the second major surface 2060 (e.g.,the concave surface following bending) increases (i.e., the compressivestress on the second major surface 2050 is greater after cold-formingthan before cold-forming).

Without being bound by theory, the cold-forming process increases thecompressive stress of the glass substrate being shaped to compensate fortensile stresses imparted during bending and/or forming operations. Inone or more embodiments, the cold-forming process causes the secondmajor surface 2060 to experience compressive stresses, while the firstmajor surface 2050 (e.g., the convex surface following bending)experiences tensile stresses. The tensile stress experienced by surface2050 following bending results in a net decrease in surface compressivestress, such that the compressive stress in surface 2050 of astrengthened glass sheet following bending is less than the compressivestress in surface 2050 when the glass sheet is flat.

Further, when a strengthened glass substrate is utilized for outer glasssubstrate 2010, the first major surface and the second major surface(2050,2060) are already under compressive stress, and thus first majorsurface 2050 can experience greater tensile stress during bendingwithout risking fracture. This allows for the strengthened embodimentsof outer glass substrate 2010 to conform to more tightly curved surfaces(e.g., shaped to have smaller R1 values).

In various embodiments, the thickness of outer glass substrate 2010 istailored to allow outer glass substrate 2010 to be more flexible toachieve the desired radius of curvature. Moreover, a thinner outer glasssubstrate 2010 may deform more readily, which could potentiallycompensate for shape mismatches and gaps that may be created by theshape of a support or frame (as discussed below). In one or moreembodiments, a thin and strengthened outer glass substrate 2010 exhibitsgreater flexibility especially during cold-forming. The greaterflexibility of the glass substrate discussed herein may allow forconsistent bend formation without heating.

In various embodiments, outer glass substrate 2010 (and consequentlydeadfront article 2000) may have a compound curve including a majorradius and a cross curvature. A complexly curved cold-formed outer glasssubstrate 2010 may have a distinct radius of curvature in twoindependent directions. According to one or more embodiments, thecomplexly curved cold-formed outer glass substrate 2010 may thus becharacterized as having “cross curvature,” where the cold-formed outerglass substrate 2010 is curved along an axis (i.e., a first axis) thatis parallel to a given dimension and also curved along an axis (i.e., asecond axis) that is perpendicular to the same dimension. The curvatureof the cold-formed outer glass substrate 2010 can be even more complexwhen a significant minimum radius is combined with a significant crosscurvature, and/or depth of bend.

Referring to FIG. 25 , display assembly 2100 is shown according to anexemplary embodiment. In the embodiment shown, display assembly 2100includes frame 2110 supporting (either directly or indirectly) both alight source, shown as a display module 2120, and deadfront article2000. As shown in FIG. 25 , deadfront article 2000 and display module2120 are coupled to frame 2110, and display module 2120 is positioned toallow a user to view light, images, etc. generated by display module2120 through deadfront article 2000. In various embodiments, frame 2110may be formed from a variety of materials such as plastic (PC/ABS,etc.), metals (Al-alloys, Mg-alloys, Fe-alloys, etc.). Various processessuch as casting, machining, stamping, injection molding, etc. may beutilized to form the curved shape of frame 2110. While FIG. 25 shows alight source in the form of a display module, it should be understoodthat display assembly 2100 may include any of the light sourcesdiscussed herein for producing graphics, icons, images, displays, etc.through any of the dead front embodiments discussed herein. Further,while frame 2110 is shown as a frame associated with a display assembly,frame 2110 may be any support or frame article associated with a vehicleinterior system.

In various embodiments, the systems and methods described herein allowfor formation of deadfront article 2000 to conform to a wide variety ofcurved shapes that frame 2110 may have. As shown in FIG. 25 , frame 2110has a support surface 2130 that has a curved shape, and deadfrontarticle 2000 is shaped to match the curved shape of support surface2130. As will be understood, deadfront structure 2000 may be shaped intoa wide variety of shapes to conform to a desired frame shape of adisplay assembly 2100, which in turn may be shaped to fit the shape of aportion of a vehicle interior system, as discussed herein.

In one or more embodiments, deadfront structure 2000 (and specificallyouter glass substrate 2010) is shaped to have a first radius ofcurvature, R1, of about 60 mm or greater. For example, R1 may be in arange from about 60 mm to about 1500 mm, from about 70 mm to about 1500mm, from about 80 mm to about 1500 mm, from about 90 mm to about 1500mm, from about 100 mm to about 1500 mm, from about 120 mm to about 1500mm, from about 140 mm to about 1500 mm, from about 150 mm to about 1500mm, from about 160 mm to about 1500 mm, from about 180 mm to about 1500mm, from about 200 mm to about 1500 mm, from about 220 mm to about 1500mm, from about 240 mm to about 1500 mm, from about 250 mm to about 1500mm, from about 260 mm to about 1500 mm, from about 270 mm to about 1500mm, from about 280 mm to about 1500 mm, from about 290 mm to about 1500mm, from about 300 mm to about 1500 mm, from about 350 mm to about 1500mm, from about 400 mm to about 1500 mm, from about 450 mm to about 1500mm, from about 500 mm to about 1500 mm, from about 550 mm to about 1500mm, from about 600 mm to about 1500 mm, from about 650 mm to about 1500mm, from about 700 mm to about 1500 mm, from about 750 mm to about 1500mm, from about 800 mm to about 1500 mm, from about 900 mm to about 1500mm, from about 9500 mm to about 1500 mm, from about 1000 mm to about1500 mm, from about 1250 mm to about 1500 mm, from about 60 mm to about1400 mm, from about 60 mm to about 1300 mm, from about 60 mm to about1200 mm, from about 60 mm to about 1100 mm, from about 60 mm to about1000 mm, from about 60 mm to about 950 mm, from about 60 mm to about 900mm, from about 60 mm to about 850 mm, from about 60 mm to about 800 mm,from about 60 mm to about 750 mm, from about 60 mm to about 700 mm, fromabout 60 mm to about 650 mm, from about 60 mm to about 600 mm, fromabout 60 mm to about 550 mm, from about 60 mm to about 500 mm, fromabout 60 mm to about 450 mm, from about 60 mm to about 400 mm, fromabout 60 mm to about 350 mm, from about 60 mm to about 300 mm, or fromabout 60 mm to about 250 mm.

In one or more embodiments, support surface 2130 has a second radius ofcurvature of about 60 mm or greater. For example, the second radius ofcurvature of support surface 2130 may be in a range from about 60 mm toabout 1500 mm, from about 70 mm to about 1500 mm, from about 80 mm toabout 1500 mm, from about 90 mm to about 1500 mm, from about 100 mm toabout 1500 mm, from about 120 mm to about 1500 mm, from about 140 mm toabout 1500 mm, from about 150 mm to about 1500 mm, from about 160 mm toabout 1500 mm, from about 180 mm to about 1500 mm, from about 200 mm toabout 1500 mm, from about 220 mm to about 1500 mm, from about 240 mm toabout 1500 mm, from about 250 mm to about 1500 mm, from about 260 mm toabout 1500 mm, from about 270 mm to about 1500 mm, from about 280 mm toabout 1500 mm, from about 290 mm to about 1500 mm, from about 300 mm toabout 1500 mm, from about 350 mm to about 1500 mm, from about 400 mm toabout 1500 mm, from about 450 mm to about 1500 mm, from about 500 mm toabout 1500 mm, from about 550 mm to about 1500 mm, from about 600 mm toabout 1500 mm, from about 650 mm to about 1500 mm, from about 700 mm toabout 1500 mm, from about 750 mm to about 1500 mm, from about 800 mm toabout 1500 mm, from about 900 mm to about 1500 mm, from about 9500 mm toabout 1500 mm, from about 1000 mm to about 1500 mm, from about 1250 mmto about 1500 mm, from about 60 mm to about 1400 mm, from about 60 mm toabout 1300 mm, from about 60 mm to about 1200 mm, from about 60 mm toabout 1100 mm, from about 60 mm to about 1000 mm, from about 60 mm toabout 950 mm, from about 60 mm to about 900 mm, from about 60 mm toabout 850 mm, from about 60 mm to about 800 mm, from about 60 mm toabout 750 mm, from about 60 mm to about 700 mm, from about 60 mm toabout 650 mm, from about 60 mm to about 600 mm, from about 60 mm toabout 550 mm, from about 60 mm to about 500 mm, from about 60 mm toabout 450 mm, from about 60 mm to about 400 mm, from about 60 mm toabout 350 mm, from about 60 mm to about 300 mm, or from about 60 mm toabout 250 mm.

In one or more embodiments, deadfront structure 2000 is cold-formed toexhibit a first radius curvature, R1, that is within 10% (e.g., about10% or less, about 9% or less, about 8% or less, about 7% or less, about6% or less, or about 5% or less) of the second radius of curvature ofsupport surface 2130 of frame 2110. For example, support surface 2130 offrame 2110 exhibits a radius of curvature of 1000 mm, deadfront article2000 is cold-formed to have a radius of curvature in a range from about900 mm to about 1100 mm.

In one or more embodiments, first major surface 2050 and/or second majorsurface 2060 of glass substrate 2010 includes a functional coating layeras described herein. The functional coating layer may cover at least aportion of first major surface 2050 and/or second major surface 2060.Exemplary functional coatings include at least one of a glare reductioncoating or surface, an anti-glare coating or surface, a scratchresistance coating, an anti-reflection coating, a half-minor coating, oreasy-to-clean coating.

Referring to FIG. 26 , a method 2200 for forming a display assembly thatincludes a cold-formed deadfront article, such as deadfront article 2000is shown. At step 2210, the method includes curving a deadfront article,such deadfront article 2000, to a curved surface of a support. Ingeneral, the support may be a frame of a display, such as frame 2110that defines a perimeter and curved shape of a vehicle display. Ingeneral, the frame includes a curved support surface, and one of themajor surfaces 2050 and 2060 of deadfront article 2000 is placed intocontact with the curved support surface.

At step 2220, the method includes securing the curved deadfront articleto the support causing the deadfront article to bend into conformity (orconform) with the curved surface of the support. In this manner, acurved deadfront article 2000, as shown in FIG. 23 , is formed from agenerally flat deadfront article to a curved deadfront article. In thisarrangement, curving the flat deadfront article forms a curved shape onthe major surface facing the support, while also causing a corresponding(but complimentary) curve to form in the major surface opposite of theframe. By bending the deadfront article directly on the curved frame,the need for a separate curved die or mold (typically needed in otherglass bending processes) may be eliminated. Further, by shaping thedeadfront directly to the curved frame, a wide range of curved radii maybe achieved in a low complexity manufacturing process.

In some embodiments, the force applied in step 2210 and/or step 2220 maybe air pressure applied via a vacuum fixture. In some other embodiments,the air pressure differential is formed by applying a vacuum to anairtight enclosure surrounding the frame and the deadfront article. Inspecific embodiments, the airtight enclosure is a flexible polymershell, such as a plastic bag or pouch. In other embodiments, the airpressure differential is formed by generating increased air pressurearound the deadfront article and the frame with an overpressure device,such as an autoclave. Air pressure provides a consistent and highlyuniform bending force (as compared to a contact-based bending method)which further leads to a robust manufacturing process. In variousembodiments, the air pressure differential is between 0.5 and 1.5atmospheres of pressure (atm), specifically between 0.7 and 1.1 atm, andmore specifically is 0.8 to 1 atm.

At step 2230, the temperature of the deadfront article is maintainedbelow the glass transition temperature of the material of the outerglass layer during steps 2210 and 2220. As such, method 2200 is acold-forming or cold-bending process. In particular embodiments, thetemperature of the deadfront article is maintained below 500 degrees C.,400 degrees C., 300 degrees C., 200 degrees C. or 100 degrees C. In aparticular embodiment, the deadfront article is maintained at or belowroom temperature during bending. In a particular embodiment, thedeadfront article is not actively heated via a heating element, furnace,oven, etc. during bending, as is the case when hot-forming glass to acurved shape.

As noted above, in addition to providing processing advantages such aseliminating expensive and/or slow heating steps, the cold-formingprocesses discussed herein are believed to generate curved deadfrontarticles with a variety of properties that are believed to be superiorto those achievable via hot-forming processes. For example, for at leastsome glass materials, heating during hot-forming processes decreasesoptical properties of curved glass substrates, and thus, the curvedglass-based deadfront articles formed utilizing the cold-bendingprocesses/systems discussed herein provide for both curved glass shapealong with improved optical qualities not believed achievable withhot-bending processes.

Further, many materials used for the various coatings and layers (e.g.,easy-to-clean coatings, anti-reflective coatings, etc.) are applied viadeposition processes, such as sputtering processes that are typicallyill-suited for coating on to a curved surface. In addition, many coatingmaterials, such as the deadfront ink/pigment materials, also are notable to survive the high temperatures associated with hot-bendingprocesses. Thus, in particular embodiments discussed herein, layer 2020is applied to outer glass substrate 2010 prior to cold-bending. Thus,the processes and systems discussed herein allow for bending of glassafter one or more coating material has been applied to the glass, incontrast to typical hot-forming processes.

At step 2220, the curved deadfront article is attached or affixed to thecurved support. In various embodiments, the attachment between thecurved deadfront article and the curved support may be accomplished viaan adhesive material. Such adhesives may include any suitable opticallyclear adhesive for bonding the deadfront article in place relative tothe display assembly (e.g., to the frame of the display). In oneexample, the adhesive may include an optically clear adhesive availablefrom 3M Corporation under the trade name 8215. The thickness of theadhesive may be in a range from about 200 μm to about 500 μm.

The adhesive material may be applied in a variety of ways. In oneembodiment, the adhesive is applied using an applicator gun and madeuniform using a roller or a draw down die. In various embodiments, theadhesives discussed herein are structural adhesives. In particularembodiments, the structural adhesives may include an adhesive selectedfrom one or more of the categories: (a) Toughened Epoxy (MasterbondEP21TDCHT-LO, 3M Scotch Weld Epoxy DP460 Off-white); (b) Flexible Epoxy(Masterbond EP21TDC-2LO, 3M Scotch Weld Epoxy 2216 B/A Gray); (c)Acrylic (LORD Adhesive 410/Accelerator 19 w/LORD AP 134 primer, LORDAdhesive 852/LORD Accelerator 25 GB, Loctite HF8000, Loctite AA4800);(d) Urethanes (3M Scotch Weld Urethane DP640 Brown); and (e) Silicones(Dow Corning 995). In some cases, structural glues available in sheetformat (such as B-staged epoxy adhesives) may be utilized. Furthermore,pressure sensitive structural adhesives such as 3M VHB tapes may beutilized. In such embodiments, utilizing a pressure sensitive adhesiveallows for the curved deadfront article to be bonded to the framewithout the need for a curing step.

In one or more embodiments, the method includes step 2240 in which thecurved deadfront is secured to a display. In one or more embodiments,the method may include securing the display to the deadfront articlebefore step 2210 and curving both the display and the deadfront articlein step 2210. In one or more embodiments, the method includes disposingor assembling the curved deadfront and display in a vehicle interiorsystem 100, 200, 300.

Referring to FIG. 27 , method 2300 for forming a display utilizing acurved deadfront article is shown and described. In some embodiments,the substrate (e.g., outer glass layer 2010) of a deadfront article isformed to curved shape at step 2310. Shaping at step 2310 may be eithercold-forming or hot-forming. At step 2320, the deadfront ink/pigmentlayer(s) (e.g., layer 2020) is applied to the substrate followingshaping to provide a curved deadfront article. Next at step 2330, thecurved deadfront article is attached to a frame, such as frame 2110 ofdisplay assembly 2100, or other frame that may be associated with avehicle interior system.

Substrate Materials

The various substrates of the deadfront articles discussed herein may beformed from any transparent material such as a polymer (e.g., PMMA,polycarbonate and the like) or glass. Suitable glass compositionsinclude soda lime glass, aluminosilicate glass, borosilicate glass,boroaluminosilicate glass, alkali-containing aluminosilicate glass,alkali-containing borosilicate glass, and alkali-containingboroaluminosilicate glass.

In some embodiments, a substrate discussed herein may be formed of a“glass-ceramic” material produced through controlled crystallization ofglass. In such embodiments, glass-ceramics have about 30% to about 90%crystallinity. Non-limiting examples of glass ceramic systems that maybe used include Li₂O×Al₂O₃×nSiO₂ (i.e. LAS system), MgO×Al₂O₃×nSiO₂(i.e. MAS system), and ZnO×Al₂O₃× nSiO₂ (i.e. ZAS system).

Unless otherwise specified, the glass compositions disclosed herein aredescribed in mole percent (mol %) as analyzed on an oxide basis.

In one or more embodiments, the glass composition may include SiO₂ in anamount in a range from about 66 mol % to about 80 mol %, from about 67mol % to about 80 mol %, from about 68 mol % to about 80 mol %, fromabout 69 mol % to about 80 mol %, from about 70 mol % to about 80 mol %,from about 72 mol % to about 80 mol %, from about 65 mol % to about 78mol %, from about 65 mol % to about 76 mol %, from about 65 mol % toabout 75 mol %, from about 65 mol % to about 74 mol %, from about 65 mol% to about 72 mol %, or from about 65 mol % to about 70 mol %, and allranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes Al₂O₃ in anamount greater than about 4 mol %, or greater than about 5 mol %. In oneor more embodiments, the glass composition includes Al₂O₃ in a rangefrom greater than about 7 mol % to about 15 mol %, from greater thanabout 7 mol % to about 14 mol %, from about 7 mol % to about 13 mol %,from about 4 mol % to about 12 mol %, from about 7 mol % to about 11 mol%, from about 8 mol % to about 15 mol %, from 9 mol % to about 15 mol %,from about 9 mol % to about 15 mol %, from about 10 mol % to about 15mol %, from about 11 mol % to about 15 mol %, or from about 12 mol % toabout 15 mol %, and all ranges and sub-ranges therebetween. In one ormore embodiments, the upper limit of Al₂O₃ may be about 14 mol %, 14.2mol %, 14.4 mol %, 14.6 mol %, or 14.8 mol %.

In one or more embodiments, glass layer(s) herein are described as analuminosilicate glass article or including an aluminosilicate glasscomposition. In such embodiments, the glass composition or articleformed therefrom includes SiO₂ and Al₂O₃ and is not a soda lime silicateglass. In this regard, the glass composition or article formed therefromincludes Al₂O₃ in an amount of about 2 mol % or greater, 2.25 mol % orgreater, 2.5 mol % or greater, about 2.75 mol % or greater, about 3 mol% or greater.

In one or more embodiments, the glass composition comprises B₂O₃ (e.g.,about 0.01 mol % or greater). In one or more embodiments, the glasscomposition comprises B₂O₃ in an amount in a range from about 0 mol % toabout 5 mol %, from about 0 mol % to about 4 mol %, from about 0 mol %to about 3 mol %, from about 0 mol % to about 2 mol %, from about 0 mol% to about 1 mol %, from about 0 mol % to about 0.5 mol %, from about0.1 mol % to about 5 mol %, from about 0.1 mol % to about 4 mol %, fromabout 0.1 mol % to about 3 mol %, from about 0.1 mol % to about 2 mol %,from about 0.1 mol % to about 1 mol %, from about 0.1 mol % to about 0.5mol %, and all ranges and sub-ranges therebetween. In one or moreembodiments, the glass composition is substantially free of B₂O₃.

As used herein, the phrase “substantially free” with respect to thecomponents of the composition means that the component is not activelyor intentionally added to the composition during initial batching, butmay be present as an impurity in an amount less than about 0.001 mol %.

In one or more embodiments, the glass composition optionally comprisesP₂O₅ (e.g., about 0.01 mol % or greater). In one or more embodiments,the glass composition comprises a non-zero amount of P₂O₅ up to andincluding 2 mol %, 1.5 mol %, 1 mol %, or 0.5 mol %. In one or moreembodiments, the glass composition is substantially free of P₂O₅.

In one or more embodiments, the glass composition may include a totalamount of R₂O (which is the total amount of alkali metal oxide such asLi₂O, Na₂O, K₂O, Rb₂O, and Cs₂O) that is greater than or equal to about8 mol %, greater than or equal to about 10 mol %, or greater than orequal to about 12 mol %. In some embodiments, the glass compositionincludes a total amount of R₂O in a range from about 8 mol % to about 20mol %, from about 8 mol % to about 18 mol %, from about 8 mol % to about16 mol %, from about 8 mol % to about 14 mol %, from about 8 mol % toabout 12 mol %, from about 9 mol % to about 20 mol %, from about 10 mol% to about 20 mol %, from about 11 mol % to about 20 mol %, from about12 mol % to about 20 mol %, from about 13 mol % to about 20 mol %, fromabout 10 mol % to about 14 mol %, or from 11 mol % to about 13 mol %,and all ranges and sub-ranges therebetween. In one or more embodiments,the glass composition may be substantially free of Rb₂O, Cs₂O or bothRb₂O and Cs₂O. In one or more embodiments, the R₂O may include the totalamount of Li₂O, Na₂O and K₂O only. In one or more embodiments, the glasscomposition may comprise at least one alkali metal oxide selected fromLi₂O, Na₂O and K₂O, wherein the alkali metal oxide is present in anamount greater than about 8 mol % or greater.

In one or more embodiments, the glass composition comprises Na₂O in anamount greater than or equal to about 8 mol %, greater than or equal toabout 10 mol %, or greater than or equal to about 12 mol %. In one ormore embodiments, the composition includes Na₂O in a range from aboutfrom about 8 mol % to about 20 mol %, from about 8 mol % to about 18 mol%, from about 8 mol % to about 16 mol %, from about 8 mol % to about 14mol %, from about 8 mol % to about 12 mol %, from about 9 mol % to about20 mol %, from about 10 mol % to about 20 mol %, from about 11 mol % toabout 20 mol %, from about 12 mol % to about 20 mol %, from about 13 mol% to about 20 mol %, from about 10 mol % to about 14 mol %, or from 11mol % to about 16 mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes less thanabout 4 mol % K₂O, less than about 3 mol % K₂O, or less than about 1 mol% K₂O. In some instances, the glass composition may include K₂O in anamount in a range from about 0 mol % to about 4 mol %, from about 0 mol% to about 3.5 mol %, from about 0 mol % to about 3 mol %, from about 0mol % to about 2.5 mol %, from about 0 mol % to about 2 mol %, fromabout 0 mol % to about 1.5 mol %, from about 0 mol % to about 1 mol %,from about 0 mol % to about 0.5 mol %, from about 0 mol % to about 0.2mol %, from about 0 mol % to about 0.1 mol %, from about 0.5 mol % toabout 4 mol %, from about 0.5 mol % to about 3.5 mol %, from about 0.5mol % to about 3 mol %, from about 0.5 mol % to about 2.5 mol %, fromabout 0.5 mol % to about 2 mol %, from about 0.5 mol % to about 1.5 mol%, or from about 0.5 mol % to about 1 mol %, and all ranges andsub-ranges therebetween. In one or more embodiments, the glasscomposition may be substantially free of K₂O.

In one or more embodiments, the glass composition is substantially freeof Li₂O. In one or more embodiments, the amount of Na₂O in thecomposition may be greater than the amount of Li₂O. In some instances,the amount of Na₂O may be greater than the combined amount of Li₂O andK₂O. In one or more alternative embodiments, the amount of Li₂O in thecomposition may be greater than the amount of Na₂O or the combinedamount of Na₂O and K₂O.

In one or more embodiments, the glass composition may include a totalamount of RO (which is the total amount of alkaline earth metal oxidesuch as CaO, MgO, BaO, ZnO and SrO) in a range from about 0 mol % toabout 2 mol %. In some embodiments, the glass composition includes anon-zero amount of RO up to about 2 mol %. In one or more embodiments,the glass composition comprises RO in an amount from about 0 mol % toabout 1.8 mol %, from about 0 mol % to about 1.6 mol %, from about 0 mol% to about 1.5 mol %, from about 0 mol % to about 1.4 mol %, from about0 mol % to about 1.2 mol %, from about 0 mol % to about 1 mol %, fromabout 0 mol % to about 0.8 mol %, from about 0 mol % to about 0.5 mol %,and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes CaO in anamount less than about 1 mol %, less than about 0.8 mol %, or less thanabout 0.5 mol %. In one or more embodiments, the glass composition issubstantially free of CaO.

In some embodiments, the glass composition comprises MgO in an amountfrom about 0 mol % to about 7 mol %, from about 0 mol % to about 6 mol%, from about 0 mol % to about 5 mol %, from about 0 mol % to about 4mol %, from about 0.1 mol % to about 7 mol %, from about 0.1 mol % toabout 6 mol %, from about 0.1 mol % to about 5 mol %, from about 0.1 mol% to about 4 mol %, from about 1 mol % to about 7 mol %, from about 2mol % to about 6 mol %, or from about 3 mol % to about 6 mol %, and allranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises ZrO₂ in anamount equal to or less than about 0.2 mol %, less than about 0.18 mol%, less than about 0.16 mol %, less than about 0.15 mol %, less thanabout 0.14 mol %, less than about 0.12 mol %. In one or moreembodiments, the glass composition comprises ZrO₂ in a range from about0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18 mol%, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol % toabout 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, from about0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about 0.10mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises SnO₂ in anamount equal to or less than about 0.2 mol %, less than about 0.18 mol%, less than about 0.16 mol %, less than about 0.15 mol %, less thanabout 0.14 mol %, less than about 0.12 mol %. In one or moreembodiments, the glass composition comprises SnO₂ in a range from about0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18 mol%, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol % toabout 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, from about0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about 0.10mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition may include an oxidethat imparts a color or tint to the glass articles. In some embodiments,the glass composition includes an oxide that prevents discoloration ofthe glass article when the glass article is exposed to ultravioletradiation. Examples of such oxides include, without limitation oxidesof: Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo.

In one or more embodiments, the glass composition includes Fe expressedas Fe₂O₃, wherein Fe is present in an amount up to (and including) about1 mol %. In some embodiments, the glass composition is substantiallyfree of Fe. In one or more embodiments, the glass composition comprisesFe₂O₃ in an amount equal to or less than about 0.2 mol %, less thanabout 0.18 mol %, less than about 0.16 mol %, less than about 0.15 mol%, less than about 0.14 mol %, less than about 0.12 mol %. In one ormore embodiments, the glass composition comprises Fe₂O₃ in a range fromabout 0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18mol %, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol %to about 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, fromabout 0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about0.10 mol %, and all ranges and sub-ranges therebetween.

Where the glass composition includes TiO₂, TiO₂ may be present in anamount of about 5 mol % or less, about 2.5 mol % or less, about 2 mol %or less or about 1 mol % or less. In one or more embodiments, the glasscomposition may be substantially free of TiO₂.

An exemplary glass composition includes SiO₂ in an amount in a rangefrom about 65 mol % to about 75 mol %, Al₂O₃ in an amount in a rangefrom about 8 mol % to about 14 mol %, Na₂O in an amount in a range fromabout 12 mol % to about 17 mol %, K₂O in an amount in a range of about 0mol % to about 0.2 mol %, and MgO in an amount in a range from about 1.5mol % to about 6 mol %. Optionally, SnO₂ may be included in the amountsotherwise disclosed herein.

Strengthened Substrate

In one or more embodiments, the substrate includes a glass material(such as outer glass substrate 2010 or other glass substrate) of any ofthe deadfront article embodiments discussed herein. In one or moreembodiments, such glass substrates may be strengthened. In one or moreembodiments, the glass substrate may be strengthened to includecompressive stress that extends from a surface to a depth of compression(DOC). The compressive stress regions are balanced by a central portionexhibiting a tensile stress. At the DOC, the stress crosses from apositive (compressive) stress to a negative (tensile) stress.

In one or more embodiments, the glass substrates used in the deadfrontarticles discussed herein may be strengthened mechanically by utilizinga mismatch of the coefficient of thermal expansion between portions ofthe glass to create a compressive stress region and a central regionexhibiting a tensile stress. In some embodiments, the glass substratemay be strengthened thermally by heating the glass to a temperatureabove the glass transition point and then rapidly quenching.

In one or more embodiments, the glass substrate used in the deadfrontarticles discussed herein may be chemically strengthening by ionexchange. In the ion exchange process, ions at or near the surface ofthe glass substrate are replaced by—or exchanged with—larger ions havingthe same valence or oxidation state. In those embodiments in which theglass substrate comprises an alkali aluminosilicate glass or soda limesilicate glass, ions in the surface layer of the article and the largerions are monovalent alkali metal cations, such as Li⁺, Na⁺, K⁺, Rb⁺, andCs⁺. Alternatively, monovalent cations in the surface layer may bereplaced with monovalent cations other than alkali metal cations, suchas Ag⁺ or the like. In such embodiments, the monovalent ions (orcations) exchanged into the glass substrate generate a stress.

Ion exchange processes are typically carried out by immersing a glasssubstrate in a molten salt bath (or two or more molten salt baths)containing the larger ions to be exchanged with the smaller ions in theglass substrate. It should be noted that aqueous salt baths may also beutilized. In addition, the composition of the bath(s) may include morethan one type of larger ion (e.g., Na+ and K+) or a single larger ion.It will be appreciated by those skilled in the art that parameters forthe ion exchange process, including, but not limited to, bathcomposition and temperature, immersion time, the number of immersions ofthe glass substrate in a salt bath (or baths), use of multiple saltbaths, additional steps such as annealing, washing, and the like, aregenerally determined by the composition of the glass substrate(including the structure of the substrate and any crystalline phasespresent) and the desired DOC and CS of the substrate that results fromstrengthening.

Exemplary molten bath composition may include nitrates, sulfates, andchlorides of the larger alkali metal ion. Typical nitrates include KNO₃,NaNO₃, LiNO₃, NaSO₄ and combinations thereof. The temperature of themolten salt bath typically is in a range from about 380° C. up to about450° C., while immersion times range from about 15 minutes up to about100 hours depending on the glass thickness, bath temperature and glass(or monovalent ion) diffusivity. However, temperatures and immersiontimes different from those described above may also be used.

In one or more embodiments, the glass substrate used to in the deadfrontarticles may be immersed in a molten salt bath of 100% NaNO₃, 100% KNO₃,or a combination of NaNO₃ and KNO₃ having a temperature from about 370°C. to about 480° C. In some embodiments, the glass substrate of adeadfront article may be immersed in a molten mixed salt bath includingfrom about 5% to about 90% KNO₃ and from about 10% to about 95% NaNO₃.In one or more embodiments, the glass substrate may be immersed in asecond bath, after immersion in a first bath. The first and second bathsmay have different compositions and/or temperatures from one another.The immersion times in the first and second baths may vary. For example,immersion in the first bath may be longer than the immersion in thesecond bath.

In one or more embodiments, the glass substrate used to form thedeadfront articles may be immersed in a molten, mixed salt bathincluding NaNO₃ and KNO₃ (e.g., 49%/51%, 50%/50%, 51%/49%) having atemperature less than about 420° C. (e.g., about 400° C. or about 380°C.). for less than about 5 hours, or even about 4 hours or less.

Ion exchange conditions can be tailored to provide a “spike” or toincrease the slope of the stress profile at or near the surface of theresulting glass substrate of a deadfront article. The spike may resultin a greater surface CS value. This spike can be achieved by single bathor multiple baths, with the bath(s) having a single composition or mixedcomposition, due to the unique properties of the glass compositions usedin the glass substrate of a deadfront article described herein.

In one or more embodiments, where more than one monovalent ion isexchanged into the glass substrate used in the deadfront articles, thedifferent monovalent ions may exchange to different depths within theglass substrate (and generate different magnitudes stresses within theglass substrate at different depths). The resulting relative depths ofthe stress-generating ions can be determined and cause differentcharacteristics of the stress profile.

CS is measured using those means known in the art, such as by surfacestress meter (FSM) using commercially available instruments such as theFSM-6000, manufactured by Orihara Industrial Co., Ltd. (Japan). Surfacestress measurements rely upon the accurate measurement of the stressoptical coefficient (SOC), which is related to the birefringence of theglass. SOC in turn is measured by those methods that are known in theart, such as fiber and four-point bend methods, both of which aredescribed in ASTM standard C770-98 (2013), entitled “Standard TestMethod for Measurement of Glass Stress-Optical Coefficient,” thecontents of which are incorporated herein by reference in theirentirety, and a bulk cylinder method. As used herein CS may be the“maximum compressive stress” which is the highest compressive stressvalue measured within the compressive stress layer. In some embodiments,the maximum compressive stress is located at the surface of the glasssubstrate. In other embodiments, the maximum compressive stress mayoccur at a depth below the surface, giving the compressive profile theappearance of a “buried peak.”

DOC may be measured by FSM or by a scattered light polariscope (SCALP)(such as the SCALP-04 scattered light polariscope available fromGlasstress Ltd., located in Tallinn Estonia), depending on thestrengthening method and conditions. When the glass substrate ischemically strengthened by an ion exchange treatment, FSM or SCALP maybe used depending on which ion is exchanged into the glass substrate.Where the stress in the glass substrate is generated by exchangingpotassium ions into the glass substrate, FSM is used to measure DOC.Where the stress is generated by exchanging sodium ions into the glasssubstrate, SCALP is used to measure DOC. Where the stress in the glasssubstrate is generated by exchanging both potassium and sodium ions intothe glass, the DOC is measured by SCALP, since it is believed theexchange depth of sodium indicates the DOC and the exchange depth ofpotassium ions indicates a change in the magnitude of the compressivestress (but not the change in stress from compressive to tensile); theexchange depth of potassium ions in such glass substrate is measured byFSM. Central tension or CT is the maximum tensile stress and is measuredby SCALP.

In one or more embodiments, the glass substrate used to form thedeadfront articles may be strengthened to exhibit a DOC that isdescribed a fraction of the thickness t of the glass substrate (asdescribed herein). For example, in one or more embodiments, the DOC maybe equal to or greater than about 0.05 t, equal to or greater than about0.1 t, equal to or greater than about 0.11 t, equal to or greater thanabout 0.12 t, equal to or greater than about 0.13 t, equal to or greaterthan about 0.14 t, equal to or greater than about 0.15 t, equal to orgreater than about 0.16 t, equal to or greater than about 0.17 t, equalto or greater than about 0.18 t, equal to or greater than about 0.19 t,equal to or greater than about 0.2 t, equal to or greater than about0.21 t. In some embodiments, The DOC may be in a range from about 0.08 tto about 0.25 t, from about 0.09 t to about 0.25 t, from about 0.18 t toabout 0.25 t, from about 0.11 t to about 0.25 t, from about 0.12 t toabout 0.25 t, from about 0.13 t to about 0.25 t, from about 0.14 t toabout 0.25 t, from about 0.15 t to about 0.25 t, from about 0.08 t toabout 0.24 t, from about 0.08 t to about 0.23 t, from about 0.08 t toabout 0.22 t, from about 0.08 t to about 0.21 t, from about 0.08 t toabout 0.2 t, from about 0.08 t to about 0.19 t, from about 0.08 t toabout 0.18 t, from about 0.08 t to about 0.17 t, from about 0.08 t toabout 0.16 t, or from about 0.08 t to about 0.15 t. In some instances,the DOC may be about 20 μm or less. In one or more embodiments, the DOCmay be about 40 μm or greater (e.g., from about 40 μm to about 300 μm,from about 50 μm to about 300 μm, from about 60 μm to about 300 μm, fromabout 70 μm to about 300 μm, from about 80 μm to about 300 μm, fromabout 90 μm to about 300 μm, from about 100 μm to about 300 μm, fromabout 110 μm to about 300 μm, from about 120 μm to about 300 μm, fromabout 140 μm to about 300 μm, from about 150 μm to about 300 μm, fromabout 40 μm to about 290 μm, from about 40 μm to about 280 μm, fromabout 40 μm to about 260 μm, from about 40 μm to about 250 μm, fromabout 40 μm to about 240 μm, from about 40 μm to about 230 μm, fromabout 40 μm to about 220 μm, from about 40 μm to about 210 μm, fromabout 40 μm to about 200 μm, from about 40 μm to about 180 μm, fromabout 40 μm to about 160 μm, from about 40 μm to about 150 μm, fromabout 40 μm to about 140 μm, from about 40 μm to about 130 μm, fromabout 40 μm to about 120 μm, from about 40 μm to about 110 μm, or fromabout 40 μm to about 100 μm.

In one or more embodiments, the glass substrate used to form thedeadfront articles may have a CS (which may be found at the surface or adepth within the glass article) of about 200 MPa or greater, 300 MPa orgreater, 400 MPa or greater, about 500 MPa or greater, about 600 MPa orgreater, about 700 MPa or greater, about 800 MPa or greater, about 900MPa or greater, about 930 MPa or greater, about 1000 MPa or greater, orabout 1050 MPa or greater.

In one or more embodiments, the glass substrate used to form thedeadfront articles may have a maximum tensile stress or central tension(CT) of about 20 MPa or greater, about 30 MPa or greater, about 40 MPaor greater, about 45 MPa or greater, about 50 MPa or greater, about 60MPa or greater, about 70 MPa or greater, about 75 MPa or greater, about80 MPa or greater, or about 85 MPa or greater. In some embodiments, themaximum tensile stress or central tension (CT) may be in a range fromabout 40 MPa to about 100 MPa.

Tactile Elements

FIGS. 37-40 illustrate a substrate 700 including one or more tactileelements. Substrate 700 includes a first surface 702, a second surface704 opposite first surface 702, and at least one edge surface 706extending between first and second surfaces 702, 704. An article (e.g.,deadfront article 400) that includes substrate 700 may include an outersurface (e.g., outer surface 480) defined by first surface 702 ofsubstrate 700. Thus, the user of the article may both see and touchfirst surface 702 of substrate 700 when interacting with the article.

Substrate 700 includes at least one visual element 710-1, 710-2 disposedon second surface 704 of substrate 700 such that the at least one visualelement may be viewed through first surface 702 thereof. Additionallyand/or alternatively, at least one visual element 710-1, 710-2 may bedisposed within the substrate 700 using known techniques (e.g., usingpigmented glass, etc.). Visual element(s) 710-1, 710-2 may be or mayinclude one or more graphics visible through first surface 702. In someembodiments, the one or more graphics may include one or more icons.

In some embodiments, at least one visual element 710-1, 710-2 may bedefined in whole or in part by an opaque layer (e.g., opaque layer 510).In some embodiments, the opaque layer may be provided to outline backliticons and/or other graphics (such as the graphic 410 and/or power button420 shown in FIGS. 2 and 3 , the icons 430 shown in FIG. 5 , or thegraphics 820 shown in FIG. 41 ). Thus, in some embodiments, the opaquelayer has interruptions in the layer that define visual element(s)710-1, 710-2. In such embodiments, opaque layer 510 may be a maskinglayer that defines visual element(s) 710-1, 710-2.

Visual element(s) 710-1, 710-2 may include one or more visual portionsarranged into at least one of: (i) one or more areas of color, (ii) oneor more lines, (iii) one or more patterns, (iv) one or more designs, (v)one or more images, (vi) one or more graphics, and (vii) one or morecombinations thereof. By way of example only, a first visual element710-1 may be a circle formed via color, lines, patterns, shading,masking, design, etc., and a second visual element 710-2 may be atriangle formed via color, lines, patterns, shading, masking, design,etc. Those skilled in the art will appreciate that the particularartistic elements comprised within visual element(s) 710-1, 710-2 arenumerous, and the illustrated examples are not limiting.

In some embodiments, visual element(s) 710-1, 710-2 may be disposed onsecond surface 704 of substrate 700, serving as an inner surface of anarticle (e.g., inner surface 490 of deadfront article 400). Thus, visualelement(s) 710-1, 710-2 may be seen by the user through first surface702 of substrate 700 but the visual element(s) 710-1, 710-2 areprotected from wear or damage by way of being disposed on second surface704 of substrate 700. As noted above, additional and/or alternativeembodiments may include the at least one visual element 710-1, 710-2disposed within substrate 700.

As illustrated in FIG. 37 , substrate 700 includes at least one tactileelement 712-1, 712-2. As will be explained herein, the combination ofthe at least one visual element 710-1, 710-2 and the at least onetactile element 712-1, 712-2 may be combined in such a way as to enhancethe look and/or the feel of an article. For example, tactile element(s)712-1, 712-2 may enhance the feel of the article in the user's hand orthe feel of an article's surface. In some embodiments, the tactileelement(s) 712-1, 712-2 may also operate in such a way that visualelement(s) 710-1, 710-2 is/are visually enhanced as compared to anarticle without tactile element(s) 712-1, 712-2. For example, a notablyvisually stimulating (depth and/or three-dimensional) effect has beendiscovered by providing visual element(s) 710-1, 710-2 on second surface704 of substrate 700 and providing tactile element(s) 712-1, 712-2 in acomplimentary fashion on first surface 702 of substrate 700. A similaraffect may be achieved for visual elements(s) 710-1, 710-2 disposedwithin substrate 700. In this regard, the complimentary nature ofproviding at least one tactile element 712-1, 712-2 may includeproviding one or more portions of surface roughness and/or small surfaceelements that complement the color(s), line(s), pattern(s), design(s),graphics, and/or image(s), etc. of at least one visual element 710-1,710-2.

A surface roughness discussed herein may be quantified, for example, asexhibiting an R_(a) surface roughness of between about 10 nm and about80 nm for a relatively smooth surface roughness (including subranges),between about 80 nm and about 300 nm for a relatively moderate surfaceroughness (including subranges), and greater than about 300 nm for arelatively rough surface roughness. For example, a relatively smoothsurface roughness may have a R_(a) surface roughness of 10 nm, 20 nm, 30nm, 40 nm, 50 nm, 60 nm, 70 nm, 80 nm, or a R_(a) surface roughness in arange having any two of these values as endpoints. As another example, arelatively moderate surface roughness may have a R_(a) surface roughnessof 80 nm, 100 nm, 125 nm, 150 nm, 175 nm, 200 nm, 225 nm, 250 nm, 275nm, or 300 nm, or R_(a) surface roughness in a range having any two ofthese values as endpoints. The height difference characteristics of thesmall surface elements discussed herein may be implemented viarelatively small elements extending away from a surface of the substrateand may be quantified, for example, as having a height of between about10 nm and about 80 nm for a relatively smooth surface roughness, betweenabout 80 nm and about 300 nm for a relatively moderate surfaceroughness, and greater than about 300 nm for a relatively rough surfaceroughness.

A surface roughness (R_(a)) is defined as the arithmetic average of thedifferences between the local surface heights and the average surfaceheight and can be described by the Equation (1):

$\begin{matrix}{R_{a} = {\frac{1}{n}{\sum\limits_{i = 1}^{n}{❘y_{i}❘}}}} & {{Equation}(1)}\end{matrix}$

where y_(i) is the local surface height relative to the average surfaceheight where the surface roughness (R_(a)) in at least three sampleareas (n) of about 100 μm by 100 μm are measured and averaged. Surfaceroughness (R_(a)) may be measured using a surface profilometer availablefrom Zygo Corp.

The aforementioned provision of providing at least one tactile element712-1, 712-2 in a commentary fashion to at least one visual element710-1, 710-2 may include providing lines, areas, designs, shapes,patterns, etc. of surface roughness and/or small surface elements onfirst surface 702 of the substrate 700 that substantially match (e.g.,are in registration with) corresponding lines, shapes, patterns,graphics, colors, etc. of at least one visual element 710-1, 710-2.

As used herein, two objects disposed or positioned in a “complimentaryfashion” means that the two objects have substantially the same overallshape, perimeter shape, design, and/or pattern, and occupy substantiallythe same relative surface area on opposing surfaces of a substrate. Inembodiments including an object formed within a substrate (e.g., avisual element disposed within a substrate), the overall shape,perimeter shape, design, and/or pattern, and the relative surface areaof such an object is the overall shape, perimeter shape, design, and/orpattern, and surface area of that object projected onto a surface of thesubstrate opposite the surface on which the corresponding object isdisposed or positioned in a complimentary fashion. FIG. 37 illustrates afirst visual element 710-1 positioned on second surface 704 in acomplementary fashion to a first tactile element 712-1 on first surface702 of substrate 700. Similarly, FIG. 37 illustrates a second visualelement 710-2 positioned on second surface 704 in a complementaryfashion to a second tactile element 712-2 on first surface 702 ofsubstrate 700.

In some embodiments, desirable visual effects may be obtained withoutdisposing objects in a complementary fashion. In some embodiments, atleast one tactile element 712-1, 712-2 may be disposed in anon-commentary fashion (e.g., offset fashion) to at least one visualelement 710-1, 710-2 to produce desirable visual effect.

Tactile element(s) 712-1, 712-2 include one or more surface roughnessportions and/or small surface elements arranged into at least one of:(i) one or more areas of surface roughness and/or small surfaceelements, (ii) one or more lines of surface roughness and/or smallsurface elements, (iii) one or more patterns of surface roughness and/orsmall surface elements, (iv) one or more designs of surface roughnessand/or small surface elements, and (v) one or more combinations thereof.By way of example only, first tactile element 712-1 may be a circleformed via a line of elevated surface roughness and/or small surfaceelements, or a line of reduced surface roughness and/or small surfaceelements, and second tactile element 712-2 may be a triangle formed viaa line of elevated surface roughness and/or small surface elements, or aline of reduced surface roughness and/or small surface elements. Again,those skilled in the art will appreciate that the particular artisticelements comprised within tactile element(s) 712-1, 712-2 are numerous.

As will be discussed herein, tactile element(s) 712-1, 712-2 may beapplied to first surface 702 of substrate 700 in such a way that firstsurface 702 serves as an outer surface of an article. First surface 702of substrate 700 may be subject to surface processing in order toprovide some level of surface roughening (e.g., a hazing effect) thatprovides some tactile feedback to the user. As described herein, thelevel of surface roughness and/or small surface elements may range froma feeling of smooth (very little or no surface roughness and/or smallsurface elements), to a feeling of velvety softness (moderate levels ofsurface roughness, such as a matte surface roughness, and/or moderatelevels of small surface elements), to a feeling of substantial roughness(higher levels of roughness and/or small surface elements) in order toachieve design goals.

As shown in FIG. 37 , at least some of the surface roughness portions(and/or small surface element portions) of tactile element(s) 712-1,712-2 are positioned on first surface 702 of substrate 700 in acomplimentary fashion with respect to at least some of the visualportions of visual element(s) 710-1, 710-2. Such an arrangement maymodify the visual effect of the visual element(s) 710-1, 710-2 as viewedthrough first surface 702 of substrate 700. For example, in someconfigurations, the complementary arrangement may provide athree-dimensional visual effect, particularly at some viewing angles.

In this example, first tactile element 712-1 positioned in acomplimentary fashion to first visual element 710-1 may be achieved viaa first surface roughness portion (and/or small surface element portion)of first tactile element 712-1 in the form of a line (e.g., a circularoutline) of complementary size and shape as the circle of first visualelement 710-1. Similarly, second tactile element 712-2 positioned in acomplimentary fashion to second visual element 710-2 may be achieved viaa second surface roughness portion (and/or small surface elementportion) of second tactile element 712-2 in the form of a line (e.g., atriangular outline) of complementary size and shape as the triangle ofsecond visual element 710-2.

The surface roughness portions (and/or small surface element portions)of tactile element(s) 712-1, 712-2 may be achieved in any number ofways. For example, the surface roughness portions (and/or small surfaceelement portion) may be defined by an area (e.g., a circle, a triangle,a circular and/or triangular area) of relatively higher surfaceroughness (and/or higher surface element height) that is positioned inthe visually complimentary fashion with respect to corresponding visualelement(s) 710-1 and/or 710-2 bordered by at least one area ofrelatively lower surface roughness(and/or lower surface element height).One way of achieving such an effect is to provide: (i) a majority of atotal surface area of first surface 702 of substrate 700 as a relativelysmooth finish of relatively low surface roughness (e.g., ranging from nosurface roughness or no surface element height to some low or moderatelevel of surface roughness, such as a matte finish surface roughness,and/or moderate level of surface element height); and (ii) the area ofrelatively higher surface roughness, and/or higher surface elementheight (e.g., the circular and/or triangular outline, circular and/ortriangular area) of tactile element(s) 712-1 and/or 712-2 as a minorityof the total surface area of first surface 702 and include at least someportions of such circular and/or triangular outline via a surfaceroughness and/or surface element height that is relatively rougher(e.g., ranging from a moderate level of surface roughness and/ormoderate surface element height to a high level of surface roughnessand/or high surface element height) as compared with the smooth finish.

Alternatively, the surface roughness portions and/or surface elementportions of tactile element(s) 712-1, 712-2 (e.g., in the form of atringle or triangular outline) may be achieved via an area of relativelylower surface roughness and/or lower surface element height that ispositioned in the visually complimentary fashion bordered by at leastone area of relatively higher surface roughness. One way of achievingsuch an effect is to provide: (i) a majority of a total surface area offirst surface 702 of substrate 700 as a relatively rough finish (e.g.,ranging from some moderate level of surface roughness, such as fromrougher than a matte finish surface roughness, and/or some moderatelevel of surface element height, to some high level of surface roughnessand/or some high level of surface element height); and (ii) the area ofrelatively lower surface roughness and/or relatively lower surfaceelement height (e.g., the circle, the triangle, the circular and/ortriangular outline) of tactile element(s) 712-1 and/or 712-2 as aminority of the total surface area of first surface 702 and include atleast some portions of such circle, triangle, circular and/or triangularoutline, via a surface roughness and/or surface element height that isrelatively smoother (e.g., ranging from no surface roughness and/or nosurface element height to some low level of surface roughness and/or lowlevel of surface element height) as compared with the rough finish.

A process for achieving the application of at least one tactile element712-1, 712-2 and at least one visual element 710-1, 710-2 to substrate700 will be discussed with reference to FIGS. 38-39 , which containschematic images of substrate 700 as it moves through the process. Stepsillustrated and described are not exhaustive; other steps can beperformed before, after, or between any of the described and illustratedsteps. In some embodiments, the steps may be performed in a differentorder. Variations of the process illustrated in FIGS. 38-39 are withinthe scope of the present disclosure.

For purposes of this example, at least one tactile element 710-1, 710-2is achieved via surface roughness characteristics. The process disclosedin FIGS. 38-39 is one in which at least one tactile element 712-1, 712-2is achieved via a majority of a total surface area of first surface 702of substrate 700 being relatively smooth and relatively higher surfaceroughness portions of at least one tactile element 712-1, 712-2 beingdisposed in a complementary fashion with respect to at least one visualelement 710-1, 710-2.

At step 750, substantially all of second surface 704 of the substrate700 is masked with an etch resistant material (e.g., with an etchresistive ink, as shown in black at step 750). Next, at least firstsurface 702 of substrate 700 is exposed (e.g., dipped, sprayed, etc.) toan acid solution (etching solution) to generate a low to medium level ofsurface roughness on first surface 702, such as a matte finish surfaceroughness. The resultant matte finish is shown in grey at step 752 inwhich the etch resistive ink has been removed to expose the relativelysmooth finish of the second surface 704 of the substrate 700 (shown inwhite at step 752). In some embodiments, second surface 704 of substrate700 may not be directly masked with an etch resistant material, butinstead may be protected from an etching solution in an alternativefashion. For example, step 752 may be performed on a substrate 700defining a portion of an article (e.g., deadfront article 400), in whichcase any portions of the article which are not intended to be etched instep 752 may be protected from the etching solution using suitablematerials or apparatuses.

In some embodiments, the etching solution used in step 752 may includehydrofluoric acid, ammonium fluoride, and a water miscible organicsolvent. In some embodiments, the etching solution in step 752 mayinclude 1-15 wt % (weight percent) hydrofluoric acid, 1-40 wt % ammoniumfluoride, 0-35 wt % water miscible organic solvent, and water. In someembodiments, the etching solution in step 752 may comprise 4-10 wt %hydrofluoric acid, 5-30 wt % ammonium fluoride, 0-25 wt % water miscibleorganic solvent, and water. In some embodiments, the water miscibleorganic solvent in the etching solution in step 752 may be an alcohol,ethylene glycol, propylene glycol, glycerol, or combinations thereof.Suitable alcohols include ethanol and iso-propanol.

At step 754, an etch resistive material (e.g., etch resistive ink mask,shown in black in step 754) is applied to first surface 702 of substrate700. In particular, the etch resistive material is applied to achievethe aforementioned tactile element(s) 712-1, 712-2 that will eventuallybe complementary to visual element(s) 710-1, 710-2. Again, substantiallyall of second surface 704 of substrate 700 may be masked or protectedfrom an etching solution in step 754 (shown in black in step 754).Substrate 700 is again exposed (e.g., dipped, sprayed, etc.) to an acid(etching) solution that is designed to polish (reduce the roughness) ofthe un-masked regions of first surface 702 of substrate 700. In someembodiments, the acid solution may also reduce the thickness ofsubstrate 700 in the un-masked regions via material removal. Theresulting matte finish and tactile elements are shown in step 756 inwhich the etch resistive material has been removed to expose thepreviously masked portions of first surface 702 (shown in dark gray atstep 756). Notably, the previously masked portions of first surface 702will thus be of a higher surface roughness than the un-masked regions ofthe first surface 702, which have been polished and somewhat thinned. Inan alternative embodiment, all portions of first surface 702 exceptthose corresponding to the position of tactile element(s) 712-1, 712-2that will eventually be complementary to visual element(s) 710-1, 710-2may be masked in step 754. In such embodiments, tactile element(s)712-1, 712-2 may lower surface roughness than un-masked regions aroundthe tactile element(s) 712-1, 712-2.

In some embodiments, the etching solution used in step 756 may includehydrofluoric acid. In some embodiments, the etching solution used instep 756 may include 1-10 wt % hydrofluoric acid. In some embodiments,the etching solution in step 756 may include 5 wt % hydrofluoric acid.

Skilled artisans will appreciate that although use of acids for etchingand/or polishing were described above as being suitable for use inapplying and/or modifying the surface roughness or haze of the substrate700, any other suitable method may be used, for example sand blasting,embossing, rolling, mechanical polishing, engraving, and/or vapordeposition (e.g., chemical or physical vapor deposition). Also, skilledartisans will appreciate that although ink printing was described as onemanner of forming the etch masks and/or visual elements, any suitablealternative techniques may be employed, for example, printing, screenprinting, doctor blading, gravure printing, photolithography, etc.

In an optional step, substrate 700 may also be exposed to astrengthening process, for example a thermal strengthening process or achemical strengthening process (known in the art as an ion exchangeprocess). In some embodiments, this optional strengthening process maybe performed after step 756.

At step 758, the at least one visual element 710-1, 710-2 is disposed onsecond surface 704 of substrate 700. This involves disposing at leastone visual element 710-1, 710-2 in such a way that it may be viewedthrough first surface 702 of substrate 700. This may involve inkprinting, ink spraying, masking technologies, coating techniques,photolithography, etc., to provide one or more visual portions arrangedinto at least one of, or defining at least one of: (i) one or more areasof color, (ii) one or more lines, (iii) one or more patterns, (iv) oneor more designs, (v) one or more images, (vi) one or more graphics, and(vii) one or more combinations thereof. In some embodiments, step 758may include disposing one or more layers to form a deadfront article.For example, a semi-transparent layer (e.g., semi-transparent layer460), a contrast layer (e.g., contrast layer 470), a color layer (e.g.,color layer 650), and/or an opaque layer (e.g., opaque layer 510) may bedisposed over second surface 704 of substrate 700 in step 758.

At step 760, a process for enhancing the visibility of at least onevisual element 710-1, 710-2 through first surface 702 of substrate 700may be carried out. For example, a bright (and preferably neutral)pigment layer, such as white, may be applied over visual element(s)710-1, 710-2 on second surface 704 by way of printing, coating,spraying, etc. The bright layer is shown in step 760 as white. In someembodiments, desirable enhancement of the visibility of visualelement(s) 710-1, 710-2 may be achieved when the “bright” layer is ashiny black and/or metallic coating applied over visual element(s)710-1, 710-2 on second surface 704.

An alternative process for achieving the application of at least onetactile element 712-1, 712-2 and at least one visual element 710-1,710-2 on substrate 700 is illustrated in FIG. 40 , which containsschematic images of substrate 700 as it moves through the alternativeprocess. For purposes of this example, at least one tactile element710-1, 710-2 is again achieved via surface roughness characteristics.The process disclosed in FIG. 40 is one in which at least one tactileelement 712-1, 712-2 is achieved via a majority of a total surface areaof first surface 702 of the substrate 700 being of a relatively highsurface roughness and relatively lower surface roughness portions of atleast one tactile element 712-1, 712-2 being disposed in a complementaryway with respect to at least one visual element 710-1, 710-2. Stepsillustrated and described are not exhaustive; other steps can beperformed before, after, or between any of the described and illustratedsteps. In some embodiments, the steps may be performed in a differentorder. Variations of the process illustrated in FIG. 40 are within thescope of the present disclosure.

At step 780, substantially all of second surface 704 of substrate 700 ismasked or protected with an etch resistive material (e.g., with an etchresistive ink, as shown in black at step 780). In some embodiments,second surface 704 of substrate 700 may not be directly masked with anetch resistant material, but instead may be protected from an etchingsolution in alternative fashion. For example, step 780 may be performedon a substrate 700 defining a portion of an article (e.g., deadfrontarticle 400), in which case any portions of the article which are notintended to be etched in step 780 may be protected from the etchingsolution using suitable materials or apparatuses.

In addition, an etch resistive material (e.g., etch resistive ink mask,as shown in black at step 780) is applied to first surface 702 ofsubstrate 700. In particular, the etch resistive material is applied tofirst surface 702 to achieve the aforementioned at least one tactileelement 712-1, 712-2.

Next, substrate 700 is exposed (e.g., dipped, sprayed, etc.) to an acidsolution to generate a low to medium level of surface roughness on theun-masked portions of first surface 702, such as a matte finish surfaceroughness. Of course, alternative embodiments may employ the acidsolution in such a way to produce higher levels of surface roughness. Atstep 782, the etch resistive material may then be removed to expose oneor more areas, lines, patterns, designs, combinations thereof, etc. thatare of a relatively smooth finish (shown in white at step 782) on firstsurface 702 among the other portions that are of a low to medium levelof surface roughness (or alternatively even higher levels of roughness,as shown in grey at step 782).

In some embodiments, the etching solution used in step 782 may includehydrofluoric acid, ammonium fluoride, and a water miscible organicsolvent. In some embodiments, the etching solution in step 782 mayinclude 1-15 wt % (weight percent) hydrofluoric acid, 1-40 wt % ammoniumfluoride, 0-35 wt % water miscible organic solvent, and water. In someembodiments, the etching solution in step 782 may comprise 4-10 wt %hydrofluoric acid, 5-30 wt % ammonium fluoride, 0-25 wt % water miscibleorganic solvent, and water. In some embodiments, the water miscibleorganic solvent in the etching solution in step 782 may be an alcohol,ethylene glycol, propylene glycol, glycerol, or combinations thereof.Suitable alcohols include ethanol and iso-propanol.

In some embodiments, the etching solution used in step 782 may includehydrofluoric acid. In some embodiments, the etching solution used instep 782 may include 1-10 wt % hydrofluoric acid. In some embodiments,the etching solution in step 756 may include 5 wt % hydrofluoric acid.

At step 784, at least one visual element 710-1, 710-2 is disposed onsecond surface 704 of substrate 700 (as shown by non-white surface 704at step 782). As previously discussed, this involves applying visualelement(s) 710-1, 710-2 in such a way that it may be viewed throughfirst surface 702. This may involve ink printing, ink spraying, masking,coating, photolithography, etc., to provide one or more visual portionsarranged into at least one of, or defining at least one of: (i) one ormore areas of color, (ii) one or more lines, (iii) one or more patterns,(iv) one or more designs, (v) one or more images, (vi) one or moregraphics, and (vii) one or more combinations thereof. In someembodiments, step 784 may include disposing one or more layers to form adeadfront article. For example, a semi-transparent layer (e.g.,semi-transparent layer 460), a contrast layer (e.g., contrast layer470), a color layer (e.g., color layer 650), and/or an opaque layer(e.g., opaque layer 510) may be disposed over second surface 704 ofsubstrate 700 in step 784.

At step 786, a process for enhancing the visibility of at least onevisual element 710-1, 710-2 through the first surface 702 of substrate700 may be carried out. For example, a bright (and preferably neutral)pigment layer, such as white, is applied over at least one visualelement 710-1, 710-2 on second surface 704 by way of printing, coating,spraying, etc., as shown by white on second surface 704 at step 786. Asmentioned above, desirable enhancement of the visibility of at least onevisual element 710-1, 710-2 may alternatively be achieved when the“bright” layer is a shiny black and/or metallic coating applied over atleast one visual element 710-1, 710-2 on second surface 704.

Skilled artisans will appreciate that although use of acids for etchingand/or polishing were described above as being suitable for use inapplying and/or modifying the surface roughness or haze of the substrate700, any other suitable method may be used, for example sand blasting,embossing, rolling, mechanical polishing, engraving, and/or vapordeposition (e.g., chemical or physical vapor deposition). Also, skilledartisans will appreciate that although ink printing was described as onemanner of forming the etch masks and/or visual elements, any suitablealternative techniques may be employed, for example, printing, screenprinting, doctor blading, gravure printing, photolithography, etc.

The processes described above with reference to FIGS. 38-40 result intwo different levels of surface roughness in order to achieve at leastone tactile element 712-1, 712-2. Skilled artisans will appreciate,however, that the noted steps in the process may be altered (e.g., byadding steps of masking, etching, polishing, and/or other techniques) inorder to achieve three or more different levels of surface roughness,which may enhance the visual and/or tactile effects of tactileelement(s) 712-1, 712-2.

Further, skilled artisans will appreciate that the processes describedabove with reference to FIGS. 38-40 may be modified to achieve analternative set of characteristics for at least one tactile element712-1, 712-2. For example, at least one tactile element 712-1, 712-2 maybe formed from at least two differing levels of surface roughness and/orsurface element heights, neither of which is the unaltered, original,smooth surface finish of substrate 700.

For example, step 780 may include the aforementioned printing ofsubstantially all of second surface 704 of substrate 700 and the etchresistive material (mask). However, prior to applying the etch resistivematerial to first surface 702, substrate 700 may be exposed (e.g.,dipped, sprayed, etc.) to an acid solution to generate some level ofsurface roughness on first surface 702, such as a matte finish surfaceroughness. Thereafter, the etch resistive material (mask) is applied tofirst surface 702 of substrate 700 (i.e., over the previously formedmatte finish) to achieve the aforementioned at least one tactile element712-1, 712-2.

Next, substrate 700 is again exposed (e.g., dipped, sprayed, etc.) to anacid solution to generate a further level of surface roughness on theun-masked portions of first surface 702, which is rougher than thepreviously produced matte finish surface roughness. At step 782, theetch resistive material may then be removed from first surface 702 toexpose one or more areas, lines, patterns, designs, combinationsthereof, etc. that are of the matte finish surface roughness(represented by the lines in white at steps 782, 784 in FIG. 40 ) amongthe other portions that are of a higher level of surface roughness(represented by the grey at steps 782, 784 in FIG. 40 ).

Next, the remainder of the process previously discussed in connectionwith steps 784 and 786 of FIG. 40 may be carried out, which wouldproduce at least one tactile element 712-1, 712-2 formed from at leasttwo differing levels of surface roughness, neither of which is theunaltered, original, smooth surface finish of substrate 700. While thisprocess results in two different levels of surface roughness in order toachieve at least one tactile element 712-1, 712-2, skilled artisans willappreciate that the steps in the process may be altered (e.g., by addingsteps of masking, etching, polishing, and/or other techniques) in orderto achieve three or more different levels of surface roughness.

FIGS. 41 and 42 illustrate a deadfront article 800 according to someembodiments. FIG. 41 illustrates article 800 when it is backlit with avisual element 810 of article 800 shown. FIG. 42 illustrates article 800when it is not backlit with tactile elements 830 of article 800 shown.

Deadfront article 800 includes a substrate 801. Substrate 801 may be thesame as or similar to any substrate discussed herein and includes afirst surface 802 a second surface 804 opposite first surface 802. Avisual element 810 may be disposed on second surface 804 of substrate801 and/or within substrate 801 such that visual element 810 may beviewed through first surface 802. Visual element 810 may include one ormore graphics 820 that may be viewed through first surface 802 whenarticle 800 is backlit (see FIG. 41 ). In some embodiments, one or moregraphics 820 includes or is an icon. In some embodiments, visual element810 may include a plurality of separate visual elements including one ormore graphics. For example, visual element 810 may include a pluralityof printed, coated, sprayed, etc. layers or materials including one ormore graphics.

As used herein, an “icon” is an area, line, shape, pattern, design,image, symbol, letter, number, logo, or combination thereof thatrepresents one or more functionalities of a device. When actuated by auser (e.g., via touch) an icon will produce a functional resultrepresented by the icon. For example, an on/off icon will power a deviceon or off. As another example, a “volume” icon will cause a device toproduce more or less sound. An icon may also be called a button.

Article 800 also includes at least one tactile element 830 formed onfirst surface 802 of substrate 801. As discussed herein, tactileelement(s) 830 may include one or more surface roughness portions, withat least one of the one or more surface roughness portions positioned onfirst surface 802 in a complimentary fashion to all or a portion ofvisual element 810. For example, tactile element(s) 830 may include oneor more surface roughness portions, with at least one of the one or moresurface roughness portions positioned on first surface 802 in acomplimentary fashion to a graphic 820. Tactile element(s) 830 create ahaptic feel for a user touching first surface 802 while preserving theappearance of a deadfronted material imagined on first surface 802(e.g., carbon fiber, stainless steel, wood, etc.) when article 800 isnot backlit. In some embodiments, tactile element(s) 830 may be faintlyvisible on first surface 802.

As used herein, a first object (e.g., tactile element) “formed on” asurface of a second object (e.g., substrate) means that the first objectis directly formed on the surface of the second object. A first objectformed on a surface of a second object may be formed by depositingmaterial on the surface, removing material from the surface, and/orchemically altering one or more surface properties of the surface.Suitable methods for forming a first object on the surface of a secondobject include, but are not limited to, etching (e.g., etching with anacid), polishing, sand blasting, engraving, embossing, rolling, and/orvapor deposition (e.g., chemical or physical vapor deposition). Forminga first object on the surface of a second object may change one or moreproperties of the surface, including, but not limited to, surfacegeometry, surface roughness, haze, and reflectivity. In someembodiments, tactile element(s) 830 may be etched surface portionsformed by, for example, an etching process described in reference toFIGS. 38-39 or FIG. 40 .

Deadfront article 800 also includes a deadfront assembly 840 disposed onsecond surface 804. Deadfront assembly 840 may include any layersdescried herein for forming a deadfront article. For example, deadfrontassembly 840 may include a semi-transparent layer (e.g.,semi-transparent layer 460), a contrast layer (e.g., contrast layer470), a color layer (e.g., color layer 650), and/or an opaque layer(e.g., opaque layer 510). As an example, FIG. 42 illustrates asemi-transparent layer 850, which is disposed on second surface 804,visible through first surface 802 when article is not backlit.

As another example, deadfront assembly 840 may include a high opticaldensity layer (e.g., opaque layer 510) disposed onto at least a portionof a contrast layer (e.g., contrast layer 470) such that the contrastlayer is located between the high optical density layer and thesemi-transparent layer. In such embodiments, the high optical densitylayer may at least in part define one or more graphics 820. In someembodiments, deadfront article 800 may include a touch panel (e.g.,touch panel 660) located behind visual element 810, the touch panelconfigured to respond to a touch by a user (e.g., a touch of one or moregraphics 820). In such embodiments, the touch panel may be configured torespond to a user's touch of graphic 820, which may be an icon.

In some embodiments, the portion of first surface 802 occupied bytactile element(s) 830 may be relatively rougher (i.e., may have ahigher surface roughness) than all or a portion of the remainder offirst surface 802. In such embodiments, tactile element(s) 830 may havea R_(a) surface roughness of greater than about 80 nm.

In some embodiments, the portion of first surface 802 occupied bytactile element(s) 830 may be relatively smoother (i.e., may have alower surface roughness) than all or a portion of the remainder of firstsurface 802. In such embodiments, all or a portion of first surface 802around tactile element(s) 830 may have a R_(a) surface roughness ofgreater than about 80 nm.

In some embodiments, deadfront article 800 may be made using aprocessing including one or more processes described herein in referenceto FIGS. 38-40 . In such embodiments, a method of forming tactileelement(s) 830 on deadfront article 800 includes forming at least onetactile element 830 on first surface 802 of substrate 801 in acomplimentary fashion to a graphic 820 of visual element 810 disposed onsecond surface 804 of substrate 801 opposite first surface 802 and/orwithin substrate 801 such that the graphic 820 may be viewed throughfirst surface 802.

Aspect (1) of this disclosure pertains to a deadfront articlecomprising: a substrate comprising: a first surface; and a secondsurface opposite the first surface; a visual element disposed on thesecond surface of the substrate and/or within the substrate such thatthe visual element may be viewed through the first surface, the visualelement comprising a graphic that may be viewed through the firstsurface; at least one tactile element formed on the first surface of thesubstrate, the at least one tactile element comprising one or moresurface roughness portions, wherein at least one of the one or moresurface roughness portions is positioned on the first surface of thesubstrate in a complimentary fashion to the graphic; a semi-transparentlayer disposed on at least a first portion of the second surface of thesubstrate, the semi-transparent layer having a region of a solid coloror of a design of two or more colors; and a contrast layer disposed onat least a portion of the region, the contrast layer configured toenhance visibility of the color of the region or to enhance contrastbetween the colors of the design of the region on the portion of theregion on which the contrast layer is disposed.

Aspect (2) of this disclosure pertains to the deadfront article ofAspect (1), wherein the one or more surface roughness portions aredefined by one of: (i) an area of relatively higher surface roughnessbordered by at least one area of relatively lower surface roughness, and(ii) an area of relatively lower surface roughness bordered by at leastone area of relatively higher surface roughness.

Aspect (3) of this disclosure pertains to the deadfront article ofAspect (1) or Aspect (2), wherein the graphic comprises an icon.

Aspect (4) of this disclosure pertains to the deadfront article of anyone of Aspects (1) through (3), wherein the one or more surfaceroughness portions comprises an etched portion of the first surface ofthe substrate.

Aspect (5) of this disclosure pertains to the deadfront article of anyone of Aspects (1) through (4), wherein: a majority of a total surfacearea of the first surface of the substrate comprises a first surfaceroughness; and the one or more surface roughness portions of the tactileelement cover a minority of the total surface area of the first surfaceand comprise a second surface roughness, which is different from thefirst surface roughness.

Aspect (6) of this disclosure pertains to the deadfront article ofAspect (5), wherein the second surface roughness is relatively rougherthan the first surface roughness.

Aspect (7) of this disclosure pertains to the deadfront article ofAspect (6), wherein the second surface roughness comprises a R_(a)surface roughness of greater than about 80 nm.

Aspect (8) of this disclosure pertains to the deadfront article ofAspect (5), wherein the first surface roughness is relatively rougherthan the second surface roughness.

Aspect (9) of this disclosure pertains to the deadfront article ofAspect (8), wherein the first surface roughness comprises a R_(a)surface roughness of greater than about 80 nm.

Aspect (10) of this disclosure pertains to the deadfront article of anyone of Aspects (1) through (9), wherein the substrate comprises amaterial selected from the group consisting of: a glass, a glassceramic, and a polymer.

Aspect (11) of this disclosure pertains to the deadfront article of anyone of Aspects (1) through (10), wherein the substrate comprisesstrengthened glass.

Aspect (12) of this disclosure pertains to the deadfront article of anyone of Aspects (1) through (11), further comprising a high opticaldensity layer disposed onto at least a portion of the contrast layersuch that the contrast layer is located between the high optical densitylayer and the semi-transparent layer.

Aspect (13) of this disclosure pertains to the deadfront article ofAspect (11), wherein the high optical density layer at least in partdefines the graphic.

Aspect (14) of this disclosure pertains to the deadfront article ofAspect (13), further comprising a color layer disposed in regions of thevisual element such that, in at least a portion of the visual elementdefined by the high optical density layer, the contrast layer is locatedbetween the semi-transparent layer and the color layer.

Aspect (15) of this disclosure pertains to the deadfront article of anyone of Aspects (1) through (14), wherein the region of thesemi-transparent layer has a design of two or more colors, the designcomprising at least one of a leather grain pattern, a wood grainpattern, a fabric pattern, a brushed metal finish pattern, and a logo.

Aspect (16) of this disclosure pertains to the deadfront article of anyone of Aspects (1) through (15), further comprising a touch panellocated behind the visual element, the touch panel configured to respondto a touch by a user.

Aspect (17) pertains to an automobile interior comprising: a deadfrontarticle comprising: a substrate comprising: a first surface; and asecond surface opposite the first surface; a visual element disposed onthe second surface of the substrate and/or within the substrate suchthat the visual element may be viewed through the first surface, thevisual element comprising a graphic that may be viewed through the firstsurface; at least one tactile element formed on the first surface of thesubstrate, the at least one tactile element comprising one or moresurface roughness portions, wherein at least one of the one or moresurface roughness portions is positioned on the first surface of thesubstrate in a complimentary fashion to the graphic; a semi-transparentlayer disposed on a second surface of the substrate layer; a contrastlayer disposed on at least a portion of the semi-transparent layer; anda high optical density layer disposed on at least a portion of thecontrast layer, the high optical density layer at least in part definingthe graphic; and a touch panel located behind the visual element, thetouch panel configured to respond to a touch by a user.

Aspect (18) pertains to the automobile interior of Aspect (17), whereinthe graphic is an icon and wherein the touch panel is configured torespond to a user's touch of the icon.

Aspect (19) pertains to the automobile interior of Aspect (17) or Aspect(18), wherein the semi-transparent layer has a region of a solid coloror of a design of two or more colors, the design comprising at least oneof a leather grain pattern, a wood grain pattern, a fabric pattern, abrushed metal finish pattern, and a logo.

Aspect (20) pertains to the automobile interior of any one of Aspects(17) through (19), wherein the high optical density layer disposed ontoat least a portion of the contrast layer such that the contrast layer islocated between the high optical density layer and the semi-transparentlayer.

Aspect (21) pertains to the automobile interior of Aspect (20), furthercomprising a color layer disposed in regions of the visual element suchthat, in at least a portion of the visual element defined by the highoptical density layer, the contrast layer is located between thesemi-transparent layer and the color layer.

Aspect (22) pertains to a method of forming a tactile element on adeadfront article, the method comprising: forming at least one tactileelement on a first surface of a substrate in a complimentary fashion toa graphic defined by a visual element disposed on a second surface ofthe substrate opposite the first surface and/or within the substratesuch that the graphic may be viewed through the first surface, whereinthe at least one tactile element is formed by a process comprising atleast one of etching, sandblasting, polishing, and engraving.

Aspect (23) pertains to the method of forming a tactile element on adeadfront article of Aspect (22), wherein the at least one tactileelement is formed by an etching process.

Aspect (24) pertains to the method of forming a tactile element on adeadfront article of Aspect (23), wherein the etching process comprises:etching the first surface with a first etching solution; disposing amask over the first surface after etching the first surface with thefirst etching solution, the mask comprising a shape corresponding to theshape of the graphic; and etching an unmasked region of the firstsurface with a second etching solution.

Aspect (25) pertains to the method of forming a tactile element on adeadfront article of Aspect (24), wherein the first etching solutioncomprises hydrofluoric acid, ammonium fluoride, and a water miscibleorganic solvent, and wherein the second etching solution compriseshydrofluoric acid.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is in no way intendedthat any particular order be inferred. In addition, as used herein, thearticle “a” is intended to include one or more than one component orelement, and is not intended to be construed as meaning only one.

It will be apparent to those skilled in the art that variousmodifications and variations can be made without departing from thespirit or scope of the disclosed embodiments. Since modifications,combinations, sub-combinations and variations of the disclosedembodiments incorporating the spirit and substance of the embodimentsmay occur to persons skilled in the art, the disclosed embodimentsshould be construed to include everything within the scope of theappended claims and their equivalents.

The term “or,” as used herein, is inclusive; more specifically, thephrase “A or B” means “A, B, or both A and B.” Exclusive “or” isdesignated herein by terms such as “either A or B” and “one of A or B,”for example.

The indefinite articles “a” and “an” to describe an element or componentmeans that one or at least one of these elements or components ispresent. Although these articles are conventionally employed to signifythat the modified noun is a singular noun, as used herein the articles“a” and “an” also include the plural, unless otherwise stated inspecific instances. Similarly, the definite article “the,” as usedherein, also signifies that the modified noun may be singular or plural,again unless otherwise stated in specific instances.

As used in the claims, “comprising” is an open-ended transitionalphrase. A list of elements following the transitional phrase“comprising” is a non-exclusive list, such that elements in addition tothose specifically recited in the list may also be present. As used inthe claims, “consisting essentially of” or “composed essentially of”limits the composition of a material to the specified materials andthose that do not materially affect the basic and novelcharacteristic(s) of the material. As used in the claims, “consistingof” or “composed entirely of” limits the composition of a material tothe specified materials and excludes any material not specified.

The term “wherein” is used as an open-ended transitional phrase, tointroduce a recitation of a series of characteristics of the structure.

Where a range of numerical values is recited herein, comprising upperand lower values, unless otherwise stated in specific circumstances, therange is intended to include the endpoints thereof, and all integers andfractions within the range. It is not intended that the scope of theclaims be limited to the specific values recited when defining a range.Further, when an amount, concentration, or other value or parameter isgiven as a range, one or more preferred ranges or a list of upperpreferable values and lower preferable values, this is to be understoodas specifically disclosing all ranges formed from any pair of any upperrange limit or preferred value and any lower range limit or preferredvalue, regardless of whether such pairs are separately disclosed.Finally, when the term “about” is used in describing a value or anend-point of a range, the disclosure should be understood to include thespecific value or end-point referred to. Whether or not a numericalvalue or end-point of a range recites “about,” the numerical value orend-point of a range is intended to include two embodiments: onemodified by “about,” and one not modified by “about.”

As used herein, the term “about” means that amounts, sizes, ranges,formulations, parameters, and other quantities and characteristics arenot and need not be exact, but may be approximate and/or larger orsmaller, as desired, reflecting tolerances, conversion factors, roundingoff, measurement error and the like, and other factors known to those ofskill in the art.

The terms “substantial,” “substantially,” and variations thereof as usedherein are intended to note that a described feature is equal orapproximately equal to a value or description. For example, a“substantially planar” surface is intended to denote a surface that isplanar or approximately planar. Moreover, “substantially” is intended todenote that two values are equal or approximately equal. In someembodiments, “substantially” may denote values within about 10% of eachother, such as within about 5% of each other, or within about 2% of eachother.

The present embodiment(s) have been described above with the aid offunctional building blocks illustrating the implementation of specifiedfunctions and relationships thereof. The boundaries of these functionalbuilding blocks have been arbitrarily defined herein for the convenienceof the description. Alternate boundaries can be defined so long as thespecified functions and relationships thereof are appropriatelyperformed.

It is to be understood that the phraseology or terminology used hereinis for the purpose of description and not of limitation. The breadth andscope of the present disclosure should not be limited by any of theabove-described exemplary embodiments, but should be defined inaccordance with the following claims and their equivalents.

What is claimed is:
 1. A deadfront article comprising: a substratecomprising: a first surface; and a second surface opposite the firstsurface; a visual element disposed on or within the substrate such thatthe visual element may be viewed through the first surface; at least onetactile element formed on the first surface of the substrate, the atleast one tactile element being disposed in a first area of the firstsurface, the first area comprising a first surface roughness, whereinthe first surface comprises a second area surrounding at least a portionof the first area having a second surface roughness that is differentfrom the first surface roughness; and a deadfront assembly disposed onthe second surface, wherein: the deadfront assembly defines one or morefirst regions of the deadfront article that at least partially containthe first area, and within the one or more first regions, the deadfrontassembly comprises an optical density that is greater than or equal to1.0 and less than or equal to 2.1.
 2. The deadfront article of claim 1,wherein: the deadfront assembly defines one or more second regions ofthe deadfront article, and within the one or more second regions, thedeadfront assembly comprises an optical density that is greater than orequal to 3.4.
 3. The deadfront article of claim 2, wherein: thedeadfront assembly comprises an opaque layer delineating boundaries ofthe one or more second regions, and a boundary of defined by the opaquelayer defines a peripheral shape of the visual element.
 4. The deadfrontarticle of claim 3, wherein the first area is disposed in acomplementary fashion to the visual element.
 5. The deadfront article ofclaim 4, wherein the first surface roughness is less than the secondsurface roughness.
 6. The deadfront article of claim 4, wherein thefirst surface roughness is greater than the second surface roughness. 7.The deadfront article of claim 4, wherein the first area has aperipheral shape that is the same as the peripheral shape of the visualelement.
 8. The deadfront article of claim 1, wherein the deadfrontassembly comprises: a semi-transparent layer disposed on at least afirst portion of the second surface of the substrate, thesemi-transparent layer having a region of a solid color or of a designof two or more colors; and a contrast layer disposed on at least aportion of the region, the contrast layer configured to enhancevisibility of the color of the region or to enhance contrast between thecolors of the design of the region on the portion of the region on whichthe contrast layer is disposed.
 9. The deadfront article of claim 8,wherein: the semi-transparent layer comprises an optical density of 0.1to 0.5, and the contrast layer is white or gray and comprises an opticaldensity of 0.9 to
 2. 10. The deadfront article of claim 9, wherein thecontrast layer comprises a whiteness of from 10 W to 60 W according toISO 11475:2004.
 11. The deadfront article of claim 1, wherein the atleast one tactile element covers a minority of a total surface area ofthe first surface.
 12. A deadfront article comprising: a substratecomprising: a first surface; and a second surface opposite the firstsurface; a visual element disposed on or within the substrate such thatthe visual element may be viewed through a first area of first surface;a tactile element formed on the first area of the first surface, whereina boundary of the tactile element corresponds with a boundary of thevisual element, wherein the first area of the first surface comprises afirst surface roughness that differs from a second surface roughness ofa second area of the first surface; and a deadfront assembly disposed onthe second surface, wherein: the deadfront assembly defines one or morefirst regions of the deadfront article that overlap with the first area,and within the one or more first regions, the deadfront assemblycomprises an optical density that is greater than or equal to 1.0 andless than or equal to 2.1.
 13. The deadfront article of claim 12,wherein: the deadfront assembly defines a second region of the deadfrontarticle that overlaps the second area of the first surface, and withinthe one or more second regions, the deadfront assembly comprises anoptical density that is greater than or equal to 3.4.
 14. The deadfrontarticle of claim 13, wherein: the deadfront assembly comprises an opaquelayer defining a boundary of the second region, and the boundary definesa peripheral shape of the visual element.
 15. The deadfront article ofclaim 12, wherein the first surface roughness is less than the secondsurface roughness.
 16. The deadfront article of claim 12, wherein thefirst surface roughness is greater than the second surface roughness.17. The deadfront article of claim 12, wherein the deadfront assemblycomprises: a semi-transparent layer disposed on at least a first portionof the second surface of the substrate, the semi-transparent layerhaving a region of a solid color or of a design of two or more colors;and a contrast layer disposed on at least a portion of the region, thecontrast layer configured to enhance visibility of the color of theregion or to enhance contrast between the colors of the design of theregion on the portion of the region on which the contrast layer isdisposed.
 18. The deadfront article of claim 17, wherein: thesemi-transparent layer comprises an optical density of 0.1 to 0.5, andthe contrast layer is white or gray and comprises an optical density of0.9 to
 2. 19. The deadfront article of claim 18, wherein the contrastlayer comprises a whiteness of from 10 W to 60 W according to ISO11475:2004.